Surgical system couplable with staple cartridge and radio frequency cartridge, and method of using same

ABSTRACT

A method is disclosed. The method includes delivering staples from a surgical staple cartridge of a surgical instrument to a first tissue during a first procedure; removing the surgical staple cartridge from the surgical instrument; and delivering radio-frequency energy from a radio-frequency cartridge of the surgical instrument to a second tissue during a second procedure.

TECHNICAL FIELD

The present disclosure relates to surgical instruments and, in variouscircumstances, surgical sealing and cutting instruments and RFcartridges and staple cartridges therefore that are designed to seal andcut tissue.

BACKGROUND

When using a surgical sealing and stapling instrument, it may be usefulto have an interchangeable portion of the surgical instrument so thatthe operator may utilize the most effective technology during variousaspects of a surgical procedure. Having an interchangeable tool assemblyallows the operator, for example, to utilize one type of end effector,performing a first function, during a first portion of a procedure thenswitch to a second type of end effector, performing a second function,during a second portion of the procedure.

SUMMARY

In one aspect, a method includes delivering staples from a surgicalstaple cartridge of a surgical instrument to a first tissue during afirst procedure; removing the surgical staple cartridge from thesurgical instrument; and delivering radio-frequency energy from aradio-frequency cartridge of the surgical instrument to a second tissueduring a second procedure.

In another aspect, a method of utilizing an interchangeable toolassembly includes utilizing a staple cartridge coupled to theinterchangeable tool assembly to deliver staples to seal a first tissueduring the first period of time; replacing the staple cartridge; andutilizing a radio-frequency cartridge coupled to the interchangeabletool assembly to deliver radio-frequency energy to seal a second tissueduring a second period of time.

In another aspect, a method includes sealing a first tissue with staplesfrom a removable staple cartridge of a surgical instrument; sterilizingthe surgical instrument; and sealing a second tissue withradio-frequency energy delivered by a removable radio-frequencycartridge of the surgical instrument.

FIGURES

The novel features of the aspects described herein are set forth withparticularity in the appended claims. These aspects, however, both as toorganization and methods of operation may be better understood byreference to the following description, taken in conjunction with theaccompanying drawings.

FIG. 1 is a perspective view of a surgical system including a handleassembly coupled to an interchangeable surgical tool assembly that isconfigured to be used in connection with conventional surgicalstaple/fastener cartridges and radio frequency (RF) cartridges accordingto one aspect of this disclosure.

FIG. 2 is an exploded perspective assembly view of the surgical systemof FIG. 1 according to one aspect of this disclosure.

FIG. 3 is another exploded perspective assembly view of portions of thehandle assembly and interchangeable surgical tool assembly of FIGS. 1and 2 according to one aspect of this disclosure.

FIG. 4 is an exploded assembly view of a proximal portion of theinterchangeable surgical tool assembly of FIGS. 1-3 according to oneaspect of this disclosure.

FIG. 5 is another exploded assembly view of a distal portion of theinterchangeable surgical tool assembly of FIGS. 1-5 according to oneaspect of this disclosure.

FIG. 6 is a partial cross-sectional view of the end effector depicted inFIGS. 1-5 supporting an RF cartridge therein and with tissue clampedbetween the cartridge and the anvil according to one aspect of thisdisclosure.

FIG. 7 is a partial cross-sectional view of the anvil of FIG. 6according to one aspect of this disclosure.

FIG. 8 is another exploded assembly view of a portion of theinterchangeable surgical tool assembly of FIGS. 1-5 according to oneaspect of this disclosure.

FIG. 9 is another exploded assembly view of the interchangeable surgicaltool assembly and handle assembly of FIGS. 1 and 2 according to oneaspect of this disclosure.

FIG. 10 is a perspective view of an RF cartridge and an elongate channelof the interchangeable surgical tool assembly of FIGS. 1-5 according toone aspect of this disclosure.

FIG. 11 is a partial perspective view of portions of the RF cartridgeand elongate channel of FIG. 10 with a knife member aspect according toone aspect of this disclosure.

FIG. 12 is another perspective view of the RF cartridge installed in theelongate channel of FIG. 10 and illustrating a portion of a flexibleshaft circuit arrangement according to one aspect of this disclosure.

FIG. 13 is a cross-sectional end view of the RF cartridge and elongatechannel of FIG. 12 taken along lines 13-13 in FIG. 12 according to oneaspect of this disclosure.

FIG. 14 is a top cross-sectional view of a portion of theinterchangeable surgical tool assembly of FIGS. 1 and 5 with the endeffector thereof in an articulated position according to one aspect ofthis disclosure.

FIG. 15 is a perspective view of an onboard circuit board arrangementand RF generator plus configuration according to one aspect of thisdisclosure.

FIGS. 16A-16B is a block diagram of a control circuit of the surgicalinstrument of FIG. 1 spanning two drawing sheets according to one aspectof this disclosure.

FIG. 17 is a block diagram of the control circuit of the surgicalinstrument of FIG. 1 illustrating interfaces between the handleassembly, the power assembly, and the handle assembly and theinterchangeable shaft assembly according to one aspect of thisdisclosure.

FIG. 18 is a schematic diagram of a surgical instrument configured tocontrol various functions according to one aspect of this disclosure.

FIG. 19 is side elevational view of the surgical instrument with thecasing removed displaying a trigger sensing assembly, wherein theclosure trigger is in the unactuated position according to one aspect ofthis disclosure.

FIG. 20 is a side elevational view if the surgical instrument with thecasing removed displaying a trigger sensing assembly, wherein theclosure trigger is in the actuated position according to one aspect ofthis disclosure.

FIG. 21 is a perspective view of an end effector comprising a tissuethickness sensing assembly according to one aspect of this disclosure.

FIG. 22 is a schematic view of a sensor of the tissue thickness sensingassembly according to one aspect of this disclosure.

FIG. 23 is an exploded perspective view of a position sensing assemblyaccording to one aspect of this disclosure.

FIG. 24 is a diagram of a circuit and a position sensor of a positionsensing assembly according to one aspect of this disclosure.

FIG. 25 is a block diagram of one example of a surgical instrumentconfigured to display various statuses of the surgical instrumentaccording to one aspect of this disclosure.

FIG. 26 is a display depicting RF energy status information of thesurgical instrument according to one aspect of this disclosure.

FIG. 27 is a display depicting RF energy status information of thesurgical instrument according to one aspect of this disclosure.

FIG. 28 is a display depicting RF energy status information of thesurgical instrument according to one aspect of this disclosure.

FIG. 29 is a display depicting RF energy status information of thesurgical instrument according to one aspect of this disclosure.

FIG. 30 is a display depicting temperature information of the surgicalinstrument according to one aspect of this disclosure.

FIG. 31 is a display depicting tissue water content information of thesurgical instrument according to one aspect of this disclosure.

FIG. 32 is a display depicting operational progress information of thesurgical instrument according to one aspect of this disclosure.

FIG. 33 is a display depicting operational progress information of thesurgical instrument according to one aspect of this disclosure.

FIG. 34 is a display depicting tissue and operational progressinformation of the surgical instrument according to one aspect of thisdisclosure.

FIG. 35 is a display depicting a warning of the surgical instrumentaccording to one aspect of this disclosure.

FIG. 36 is a display depicting a warning of the surgical instrumentaccording to one aspect of this disclosure.

FIG. 37 is a display depicting status, operational progress, and tissueinformation of the surgical instrument according to one aspect of thisdisclosure.

FIG. 38 is a display depicting RF cartridge status information of thesurgical instrument according to one aspect of this disclosure.

FIG. 39 is a display depicting RF cartridge status information of thesurgical instrument according to one aspect of this disclosure

FIG. 40 shows a nozzle assembly that constitutes a modular portion ofthe surgical tool assembly may include shaft module circuitry uniquelyconfigured to control various functions in the shaft assembly while alsocommunicating with the handle assembly and allowing for anelectrosurgical generator to be controlled from the powered staplinghandle, according to some aspects.

FIG. 41 illustrates a block diagram of a surgical system programmed tocommunicate power and control signals with an end effector, according toone aspect of this disclosure.

FIG. 42 is a schematic top view of a jaw in an end effector according toone aspect of this disclosure.

FIG. 43 is a graph depicting voltage applied to electrodes as a functionof time according to one aspect of this disclosure.

FIG. 44 is a logic flow diagram depicting a process of a control programor a logic configuration for operating the surgical instrument accordingto one aspect of this disclosure.

FIG. 45 is a graph of a tissue impedance curve as a function of timeaccording to one aspect of this disclosure.

FIG. 46 is a graph depicting an example motor voltage curve according toone aspect of this disclosure.

FIG. 47 is a logic flow diagram depicting a process of a control programor a logic configuration for operating the surgical instrument accordingto one aspect of this disclosure.

FIG. 48 is a graph of a tissue impedance curve as a function of timeaccording to one aspect of this disclosure.

FIG. 49 is a graph depicting an example motor voltage curve according toone aspect of this disclosure.

FIG. 50 is a top cross-section view of an aspect of a flexible assemblydepicted in FIG. 14 according to one aspect of this disclosure.

FIG. 51A is a top cross-section view of an aspect of the flexibleassembly depicted in FIG. 14 for a knife member disposed at a proximalposition as disposed within an aspect of an electrosurgical deviceaccording to one aspect of this disclosure.

FIG. 51B is a top cross-section view of an aspect of the flexibleassembly depicted in FIG. 14 for a knife member disposed at a distalposition disposed within an aspect of an electrosurgical deviceaccording to one aspect of this disclosure.

FIG. 52A is a top cross-section view of an aspect of the flexibleassembly depicted in FIG. 14 for a knife member disposed at a proximalposition according to one aspect of this disclosure.

FIG. 52B is a top cross-section view of an aspect of the flexibleassembly depicted in FIG. 14 for a knife member disposed at a distalposition according to one aspect of this disclosure.

FIG. 53 is a perspective view of various aspects of a surgical systemaccording to one aspect of this disclosure.

FIG. 54 is a partial cross-section of an end effector of the surgicalsystem of FIG. 53 according to one aspect of this disclosure.

FIG. 55 is a partial perspective view of a radio-frequency cartridgesupported by an elongate channel of the end effector of FIG. 54according to one aspect of this disclosure.

FIG. 56 is an exploded perspective assembly view of portions of a handleassembly and an interchangeable tool assembly of the surgical system ofFIG. 53 according to one aspect of this disclosure.

FIG. 57 is a cross-sectional view of a jaw member comprising anelectrosurgical cartridge supported by an elongated channel, accordingto some aspects of the present disclosure.

FIG. 58 is a diagram illustrating an operation of a first electrode,according to some aspects of the present disclosure.

FIG. 59 is a diagram illustrating an operation of a second electrode,according to some aspects of the present disclosure.

FIG. 60 is a logic flow diagram of a process depicting a control programor a logic configuration for applying therapeutic electrosurgical energyaccording to one aspect of this disclosure.

FIG. 61 is a schematic cross-sectional view of an electrosurgical endeffector according to one aspect of this disclosure.

FIG. 62 is a perspective view of an end effector according to one aspectof this disclosure.

FIG. 63A is a perspective view of an aspect of an end effector in anopen configuration.

FIG. 63B is a side cross-section view of the aspect of the end effectordepicted in FIG. 63A.

FIG. 64 is a diagram of aspects of surface features that may be disposedalong a shear electrode as depicted in FIG. 63A.

FIG. 65 is a perspective view of a staple cartridge of theinterchangeable surgical tool assembly of FIGS. 1-5 according to oneaspect of this disclosure.

FIG. 66 illustrates a method of utilizing the interchangeable toolassembly of FIG. 1 according to various aspects.

DESCRIPTION

Applicant of the present application owns the following patentapplications filed on Jun. 28, 2017 and which are each hereinincorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/636,103, titled SYSTEMS AND METHODSOF DISPLAYING SURGICAL INSTRUMENT STATUS, by inventors Jeffrey D.Messerly et al., filed Jun. 28, 2017.

U.S. patent application Ser. No. 15/636,110, titled SHAFT MODULECIRCUITRY ARRANGEMENTS, by inventors Jeffrey D. Messerly et al., filedJun. 28, 2017.

U.S. patent application Ser. No. 15/636,116, titled SYSTEMS AND METHODSFOR CONTROLLING CONTROL CIRCUITS FOR INDEPENDENT ENERGY DELIVERY OVERSEGMENTED SECTIONS, by inventors Jeffrey D. Messerly et al., filed Jun.28, 2017.

U.S. patent application Ser. No. 15/636,123, titled FLEXIBLE CIRCUITARRANGEMENT FOR SURGICAL FASTENING INSTRUMENTS, by inventors Jeffrey D.Messerly et al., filed Jun. 28, 2017.

U.S. patent application Ser. No. 15/636,134, titled SURGICAL SYSTEMCOUPLEABLE WITH STAPLE CARTRIDGE AND RADIO FREQUENCY CARTRIDGE, ANDHAVING A PLURALITY OF RADIO-FREQUENCY ENERGY RETURN PATHS, by inventorsJeffrey D. Messerly et al., filed Jun. 28, 2017.

U.S. patent application Ser. No. 15/636,144, titled SYSTEMS AND METHODSFOR CONTROLLING CONTROL CIRCUITS FOR AN INDEPENDENT ENERGY DELIVERY OVERSEGMENTED SECTIONS, by inventors David C. Yates et al., filed Jun. 28,2017.

U.S. patent application Ser. No. 15/636,150, titled SURGICAL ENDEFFECTOR FOR APPLYING ELECTROSURGICAL ENERGY TO DIFFERENT ELECTRODES ONDIFFERENT TIME PERIODS, by inventors Tamara Widenhouse et al., filedJun. 28, 2017.

U.S. patent application Ser. No. 15/636,162, titled ELECTROSURGICALCARTRIDGE FOR USE IN THIN PROFILE SURGICAL CUTTING AND STAPLINGINSTRUMENT, by inventors Tamara Widenhouse et al., filed Jun. 28, 2017.

U.S. patent application Ser. No. 15/636,169, titled SURGICAL ENDEFFECTOR TO ADJUST JAW COMPRESSION, by inventors Frederick E. Shelton,IV et al., filed Jun. 28, 2017.

U.S. patent application Ser. No. 15/636,177, titled CARTRIDGEARRANGEMENTS FOR SURGICAL CUTTING AND FASTENING INSTRUMENTS WITH LOCKOUTDISABLEMENT FEATURES, by inventors Jason L. Harris et al., filed Jun.28, 2017.

U.S. patent application Ser. No. 15/636,180, titled SURGICAL CUTTING ANDFASTENING INSTRUMENTS WITH DUAL POWER SOURCES, by inventors Jeffrey D.Messerly et al., filed Jun. 28, 2017.

Electrosurgical devices may be used in many surgical operations.Electrosurgical devices may apply electrical energy to tissue in orderto treat tissue. An electrosurgical device may comprise an instrumenthaving a distally mounted end effector comprising one or moreelectrodes. The end effector can be positioned against tissue such thatelectrical current may be introduced into the tissue. Electrosurgicaldevices can be configured for monopolar or bipolar operation. Duringmonopolar operation, current may be introduced into the tissue by anactive (or source) electrode on the end effector and returned through areturn electrode. The return electrode may be a grounding pad andseparately located on a patient's body. During bipolar operation,current may be introduced into and returned from the tissue by theactive and return electrodes, respectively, of the end effector.

The end effector may include two or more jaw members. At least one ofthe jaw members may have at least one electrode. At least one jaw may bemoveable from a position spaced apart from the opposing jaw forreceiving tissues to a position in which the space between the jawmembers is less than that of the first position. This movement of themoveable jaw may compress the tissue held between. Heat generated by thecurrent flow through the tissue in combination with the compressionachieved by the jaw's movement may form hemostatic seals within thetissue and/or between tissues and, thus, may be particularly useful forsealing blood vessels, for example. The end effector may comprise acutting member. The cutting member may be movable relative to the tissueand the electrodes to transect the tissue.

Electrosurgical devices also may include mechanisms to clamp tissuetogether, such as a stapling device, and/or mechanisms to sever tissue,such as a tissue knife. An electrosurgical device may include a shaftfor placing the end effector proximate to tissue undergoing treatment.The shaft may be straight or curved, bendable or non-bendable. In anelectrosurgical device including a straight and bendable shaft, theshaft may have one or more articulation joints to permit controlledbending of the shaft. Such joints may permit a user of theelectrosurgical device to place the end effector in contact with tissueat an angle to the shaft when the tissue being treated is not readilyaccessible using an electrosurgical device having a straight,non-bending shaft.

Electrical energy applied by electrosurgical devices can be transmittedto the instrument by a generator in communication with the hand piece.The electrical energy may be in the form of radio frequency (“RF”)energy. RF energy is a form of electrical energy that may be in thefrequency range of 200 kilohertz (kHz) to 1 megahertz (MHz). Inapplication, an electrosurgical instrument can transmit low frequency RFenergy through tissue, which causes ionic agitation, or friction, ineffect resistive heating, thereby increasing the temperature of thetissue. Because a sharp boundary is created between the affected tissueand the surrounding tissue, surgeons can operate with a high level ofprecision and control, without sacrificing un-targeted adjacent tissue.The low operating temperatures of RF energy is useful for removing,shrinking, or sculpting soft tissue while simultaneously sealing bloodvessels. RF energy works particularly well on connective tissue, whichis primarily comprised of collagen and shrinks when contacted by heat.

The RF energy may be in a frequency range described in EN60601-2-2:2009+A11:2011, Definition 201.3.218—HIGH FREQUENCY. Forexample, the frequency in monopolar RF applications may be typicallyrestricted to less than 5 MHz. However, in bipolar RF applications, thefrequency can be almost anything. Frequencies above 200 kHz can betypically used for monopolar applications in order to avoid the unwantedstimulation of nerves and muscles that would result from the use of lowfrequency current. Lower frequencies may be used for bipolarapplications if the risk analysis shows the possibility of neuromuscularstimulation has been mitigated to an acceptable level. Normally,frequencies above 5 MHz are not used in order to minimize the problemsassociated with high frequency leakage currents. Higher frequencies may,however, be used in the case of bipolar applications. It is generallyrecognized that 10 mA is the lower threshold of thermal effects ontissue.

FIGS. 1 and 2 depict a motor-driven surgical system 10 that may be usedto perform a variety of different surgical procedures. In theillustrated arrangement, the surgical system 10 comprises aninterchangeable surgical tool assembly 1000 that is operably coupled toa handle assembly 500. In another surgical system aspect, theinterchangeable surgical tool assembly 1000 may also be effectivelyemployed with a tool drive assembly of a robotically controlled orautomated surgical system. For example, the surgical tool assembly 1000disclosed herein may be employed with various robotic systems,instruments, components and methods such as, but not limited to, thosedisclosed in U.S. Pat. No. 9,072,535, entitled SURGICAL STAPLINGINSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, which ishereby incorporated by reference herein in its entirety.

In the illustrated aspect, the handle assembly 500 may comprise a handlehousing 502 that includes a pistol grip portion 504 that can be grippedand manipulated by the clinician. As will be briefly discussed below,the handle assembly 500 operably supports a plurality of drive systemsthat are configured to generate and apply various control motions tocorresponding portions of the interchangeable surgical tool assembly1000. As shown in FIG. 2, the handle assembly 500 may further include ahandle frame 506 that operably supports the plurality of drive systems.For example, the handle frame 506 can operably support a “first” orclosure drive system, generally designated as 510, which may be employedto apply closing and opening motions to the interchangeable surgicaltool assembly 1000. In at least one form, the closure drive system 510may include an actuator in the form of a closure trigger 512 that ispivotally supported by the handle frame 506. Such arrangement enablesthe closure trigger 512 to be manipulated by a clinician such that whenthe clinician grips the pistol grip portion 504 of the handle assembly500, the closure trigger 512 may be easily pivoted from a starting or“unactuated” position to an “actuated” position and more particularly toa fully compressed or fully actuated position. In use, to actuate theclosure drive system 510, the clinician depresses the closure trigger512 towards the pistol grip portion 504. As described in further detailin U.S. patent application Ser. No. 14/226,142, entitled SURGICALINSTRUMENT COMPRISING A SENSOR SYSTEM, now U.S. Patent ApplicationPublication No. 2015/0272575, which is hereby incorporated by referencein its entirety herein, when the clinician fully depresses the closuretrigger 512 to attain the full closure stroke, the closure drive system510 is configured to lock the closure trigger 512 into the fullydepressed or fully actuated position. When the clinician desires tounlock the closure trigger 512 to permit it to be biased to theunactuated position, the clinician simply activates a closure releasebutton assembly 518 which enables the closure trigger to return tounactuated position. The closure release button assembly 518 may also beconfigured to interact with various sensors that communicate with amicrocontroller in the handle assembly 500 for tracking the position ofthe closure trigger 512. Further details concerning the configurationand operation of the closure release button assembly 518 may be found inU.S. Patent Application Publication No. 2015/0272575.

In at least one form, the handle assembly 500 and the handle frame 506may operably support another drive system referred to herein as a firingdrive system 530 that is configured to apply firing motions tocorresponding portions of the interchangeable surgical tool assemblythat is attached thereto. As was described in detail in U.S. PatentApplication Publication No. 2015/0272575, the firing drive system 530may employ an electric motor 505 that is located in the pistol gripportion 504 of the handle assembly 500. In various forms, the motor 505may be a DC brushed driving motor having a maximum rotation of,approximately, 25,000 RPM, for example. In other arrangements, the motor505 may include a brushless motor, a cordless motor, a synchronousmotor, a stepper motor, or any other suitable electric motor. The motor505 may be powered by a power source 522 that in one form may comprise aremovable power pack. The power pack may support a plurality of LithiumIon (“LI”) or other suitable batteries therein. A number of batteriesmay be connected in series may be used as the power source 522 for thesurgical system 10. In addition, the power source 522 may be replaceableand/or rechargeable.

The electric motor 505 is configured to axially drive a longitudinallymovable drive member 540 (FIG. 3) in a distal and proximal directionsdepending upon the polarity of the motor. For example, when the motor505 is driven in one rotary direction, the longitudinally movable drivemember will be axially driven in a distal direction “DD”. When the motor505 is driven in the opposite rotary direction, the longitudinallymovable drive member 540 will be axially driven in a proximal direction“PD”. The handle assembly 500 can include a switch 513 which can beconfigured to reverse the polarity applied to the electric motor 505 bythe power source 522 or otherwise control the motor 505. The handleassembly 500 can also include a sensor or sensors (not shown) that isconfigured to detect the position of the drive member and/or thedirection in which the drive member is being moved. Actuation of themotor 505 can be controlled by a firing trigger (not shown) that isadjacent to the closure trigger 512 and pivotally supported on thehandle assembly 500. The firing trigger may be pivoted between anunactuated position and an actuated position. The firing trigger may bebiased into the unactuated position by a spring or other biasingarrangement such that when the clinician releases the firing trigger, itmay be pivoted or otherwise returned to the unactuated position by thespring or biasing arrangement. In at least one form, the firing triggercan be positioned “outboard” of the closure trigger 512. As discussed inU.S. Patent Application Publication No. 2015/0272575, the handleassembly 500 may be equipped with a firing trigger safety button (notshown) to prevent inadvertent actuation of the firing trigger. When theclosure trigger 512 is in the unactuated position, the safety button iscontained in the handle assembly 500 where the clinician cannot readilyaccess it and move it between a safety position preventing actuation ofthe firing trigger and a firing position wherein the firing trigger maybe fired. As the clinician depresses the closure trigger, the safetybutton and the firing trigger pivot down wherein they can then bemanipulated by the clinician.

In at least one form, the longitudinally movable drive member 540 mayhave a rack of teeth 542 formed thereon for meshing engagement with acorresponding drive gear arrangement (not shown) that interfaces withthe motor. See FIG. 3. Further details regarding those features may befound in U.S. Patent Application Publication No. 2015/0272575. In atleast one arrangement, however, the longitudinally movable drive memberis insulated to protect it from inadvertent RF energy. At least one formalso includes a manually-actuatable “bailout” assembly that isconfigured to enable the clinician to manually retract thelongitudinally movable drive member should the motor 505 becomedisabled. The bailout assembly may include a lever or bailout handleassembly that is stored within the handle assembly 500 under areleasable door 550. See FIG. 2. The lever may be configured to bemanually pivoted into ratcheting engagement with the teeth in the drivemember. Thus, the clinician can manually retract the drive member 540 byusing the bailout handle assembly to ratchet the drive member in theproximal direction “PD”. U.S. Pat. No. 8,608,045, entitled POWEREDSURGICAL CUTTING AND STAPLING APPARATUS WITH MANUALLY RETRACTABLE FIRINGSYSTEM, the entire disclosure of which is hereby incorporated byreference herein, discloses bailout arrangements and other components,arrangements and systems that may also be employed with any one of thevarious interchangeable surgical tool assemblies disclosed herein.

In the illustrated aspect, the interchangeable surgical tool assembly1000 includes a surgical end effector 1500 that comprises a first jaw1600 and a second jaw 1800. In one arrangement, the first jaw comprisesan elongate channel 1602 that is configured to operably support aconventional (mechanical) surgical staple/fastener cartridge 1400 (FIG.4) or a radio frequency (RF) cartridge 1700 (FIGS. 1 and 2) therein. Thesecond jaw 1800 comprises an anvil 1810 that is pivotally supportedrelative to the elongate channel 1602. The anvil 1810 may be isselectively moved toward and away from a surgical cartridge supported inthe elongate channel 1602 between open and closed positions by actuatingthe closure drive system 510. In the illustrated arrangement, the anvil1810 is pivotally supported on a proximal end portion of the elongatechannel 1602 for selective pivotal travel about a pivot axis that istransverse to the shaft axis SA. Actuation of the closure drive system510 may result in the distal axial movement of a proximal closure memberor proximal closure tube 1910 that is attached to an articulationconnector 1920.

Turning to FIG. 4, the articulation connector 1920 includes upper andlower tangs 1922, 1924 protrude distally from a distal end of thearticulation connector 1920 to be movably coupled to an end effectorclosure sleeve or distal closure tube segment 1930. See FIG. 3. Thedistal closure tube segment 1930 includes an upper tang 1932 and a lowertang (not shown) that protrude proximally from a proximal end thereof.An upper double pivot link 1940 includes proximal and distal pins 1941,1942 that engage corresponding holes in the upper tangs 1922, 1932 ofthe articulation connector 1920 and distal closure tube segment 1930,respectively. Similarly, a lower double pivot link 1944 includesproximal and distal pins 1945, 1946 that engage corresponding holes inthe lower tangs 1924 of the articulation connector 1920 and distalclosure tube segment 1930, respectively.

Still referring to FIG. 4, in the illustrated example, the distalclosure tube segment 1930 includes positive jaw opening features or tabs1936, 1938 that correspond with corresponding portions of the anvil 1810to apply opening motions to the anvil 1810 as the distal closure tubesegment 1930 is retracted in the proximal direction PD to a startingposition. Further details regarding the opening and closing of the anvil1810 may be found in U.S. patent application Ser. No. 15/635,621entitled SURGICAL INSTRUMENT WITH POSITIVE JAW OPENING FEATURES, filedon Jun. 28, 2017, the entire disclosure of which is hereby incorporatedby reference herein.

As shown in FIG. 5, in at least one arrangement, the interchangeablesurgical tool assembly 1000 includes a tool frame assembly 1200 thatcomprises a tool chassis 1210 that operably supports a nozzle assembly1240 thereon. As further discussed in detail in U.S. patent applicationSer. No. 15/635,631 entitled SURGICAL INSTRUMENT WITH AXIALLY MOVABLECLOSURE MEMBER, filed on Jun. 28, 2017, and which is hereby incorporatedby reference in its entirety herein, the tool chassis 1210 and nozzlearrangement 1240 facilitate rotation of the surgical end effector 1500about a shaft axis SA relative to the tool chassis 1210. Such rotationaltravel is represented by arrow R in FIG. 1. As also shown in FIGS. 4 and5, the interchangeable surgical tool assembly 1000 includes a spineassembly 1250 that operably supports the proximal closure tube 1910 andis coupled to the surgical end effector 1500. In various circumstances,for ease of assembly, the spine assembly 1250 may be fabricated from anupper spine segment 1251 and a lower spine segment 1252 that areinterconnected together by snap features, adhesive, welding, etc. Inassembled form, the spine assembly 1250 includes a proximal end 1253that is rotatably supported in the tool chassis 1210. In onearrangement, for example, the proximal end 1253 of the spine assembly1250 is attached to a spine bearing (not shown) that is configured to besupported within the tool chassis 1210. Such arrangement facilitatesrotatable attachment of the spine assembly 1250 to the tool chassis suchthat the spine assembly 1250 may be selectively rotated about a shaftaxis SA relative to the tool chassis 1210.

As shown in FIG. 4, the upper spine segment 1251 terminates in an upperlug mount feature 1260 and the lower spine segment 1252 terminates in alower lug mount feature 1270. The upper lug mount feature 1260 is formedwith a lug slot 1262 therein that is adapted to mountingly support anupper mounting link 1264 therein. Similarly, the lower lug mount feature1270 is formed with a lug slot 1272 therein that is adapted tomountingly support a lower mounting link 1274 therein. The uppermounting link 1264 includes a pivot socket 1266 therein that is offsetfrom the shaft axis SA. The pivot socket 1266 is adapted to rotatablyreceive therein a pivot pin 1634 that is formed on a channel cap oranvil retainer 1630 that is attached to a proximal end portion 1610 ofthe elongate channel 1602. The lower mounting link 1274 includes lowerpivot pin 1276 that adapted to be received within a pivot hole 1611formed in the proximal end portion 1610 of the elongate channel 1602.The lower pivot pin 1276 as well as the pivot hole 1611 is offset fromthe shaft axis SA. The lower pivot pin 1276 is vertically aligned withthe pivot socket 1266 to define the articulation axis AA about which thesurgical end effector 1500 may articulate relative to the shaft axis SA.See FIG. 1. Although the articulation axis AA is transverse to the shaftaxis SA, in at least one arrangement, the articulation axis AA islaterally offset therefrom and does not intersect the shaft axis SA.

Turning to FIG. 5, a proximal end 1912 of the proximal closure tube 1910is rotatably coupled to a closure shuttle 1914 by a connector 1916 thatis seated in an annular groove 1915 in the proximal closure tube segment1910. The closure shuttle 1914 is supported for axial travel within thetool chassis 1210 and has a pair of hooks 1917 thereon configured toengage the closure drive system 510 when the tool chassis 1210 iscoupled to the handle frame 506. The tool chassis 1210 further supportsa latch assembly 1280 for releasably latching the tool chassis 1210 tothe handle frame 506. Further details regarding the tool chassis 1210and latch assembly 1280 may be found in U.S. patent application Ser. No.15/635,631 entitled SURGICAL INSTRUMENT WITH AXIALLY MOVABLE CLOSUREMEMBER, filed on Jun. 28, 2017 and which is the entire disclosure ofwhich is hereby incorporated by reference herein.

The firing drive system 530 in the handle assembly 500 is configured tobe operably coupled to a firing system 1300 that is operably supportedin the interchangeable surgical tool assembly 1000. The firing system1300 may include an intermediate firing shaft portion 1310 that isconfigured to be axially moved in the distal and proximal directions inresponse to corresponding firing motions applied thereto by the firingdrive system 530. See FIG. 4. As shown in FIG. 5, a proximal end 1312 ofthe intermediate firing shaft portion 1310 has a firing shaft attachmentlug 1314 formed thereon that is configured to be seated into anattachment cradle 544 (FIG. 3) that is on the distal end of thelongitudinally movable drive member 540 of the firing drive system 530within the handle assembly 500. Such arrangement facilitates the axialmovement of the intermediate firing shaft portion 1310 upon actuation ofthe firing drive system 530. In the illustrated example, theintermediate firing shaft portion 1310 is configured for attachment to adistal cutting portion or knife bar 1320. As shown in FIG. 4, the knifebar 1320 is connected to a firing member or knife member 1330. The knifemember 1330 comprises a knife body 1332 that operably supports a tissuecutting blade 1334 thereon. The knife body 1332 may further includeanvil engagement tabs or features 1336 and channel engagement featuresor a foot 1338. The anvil engagement features 1336 may serve to applyadditional closure motions to the anvil 1810 as the knife member 1330 isadvanced distally through the end effector 1500.

In the illustrated example, the surgical end effector 1500 isselectively articulatable about the articulation axis AA by anarticulation system 1360. In one form, the articulation system 1360includes proximal articulation driver 1370 that is pivotally coupled toan articulation link 1380. As can be most particularly seen in FIG. 4,an offset attachment lug 1373 is formed on a distal end 1372 of theproximal articulation driver 1370. A pivot hole 1374 is formed in theoffset attachment lug 1373 and is configured to pivotally receivetherein a proximal link pin 1382 formed on the proximal end 1381 of thearticulation link 1380. A distal end 1383 of the articulation link 1380includes a pivot hole 1384 that is configured to pivotally receivetherein a channel pin 1618 formed on the proximal end portion 1610 ofthe elongate channel 1602. Thus, axial movement of proximal articulationdriver 1370 will thereby apply articulation motions to the elongatechannel 1602 to thereby cause the surgical end effector 1500 toarticulate about the articulation axis AA relative to the spine assembly1250. In various circumstances, the proximal articulation driver 1370can be held in position by an articulation lock 1390 when the proximalarticulation driver 1370 is not being moved in the proximal or distaldirections. Further details regarding an example form of articulationlock 1390 may be found in U.S. patent application Ser. No. 15/635,837,entitled SURGICAL INSTRUMENT COMPRISING AN ARTICULATION SYSTEM LOCKABLETO A FRAME, filed on Jun. 28, 2017, the entire disclosure of which ishereby incorporated by reference herein.

Further to the above, the interchangeable surgical tool assembly 1000can include a shifter assembly 1100 which can be configured toselectively and releasably couple the proximal articulation driver 1310to the firing system 1300. As illustrated in FIG. 5, for example, in oneform, the shifter assembly 1100 includes a lock collar, or lock sleeve1110, positioned around the intermediate firing shaft portion 1310 ofthe firing system 1300 wherein the lock sleeve 1110 can be rotatedbetween an engaged position in which the lock sleeve 1110 operablycouples the proximal articulation driver 1370 to the firing memberassembly 1300 and a disengaged position in which the proximalarticulation driver 1370 is not operably coupled to the firing memberassembly 1300. When lock sleeve 1110 is in its engaged position, distalmovement of the firing member assembly 1300 can move the proximalarticulation driver 1370 distally and, correspondingly, proximalmovement of the firing member assembly 1300 can move the proximalarticulation driver 1370 proximally. When lock sleeve 1110 is in itsdisengaged position, movement of the firing member assembly 1300 is nottransmitted to the proximal articulation driver 1370 and, as a result,the firing member assembly 1300 can move independently of the proximalarticulation driver 1370. In various circumstances, the proximalarticulation driver 1370 can be held in position by the articulationlock 1390 when the proximal articulation driver 1370 is not being movedin the proximal or distal directions by the firing member assembly 1300.

In the illustrated arrangement, the intermediate firing shaft portion1310 of the firing member assembly 1300 is formed with two opposed flatsides with a drive notch 1316 formed therein. See FIG. 5. As can also beseen in FIG. 5, the lock sleeve 1110 comprises a cylindrical, or an atleast substantially cylindrical, body that includes a longitudinalaperture that is configured to receive the intermediate firing shaftportion 1310 therethrough. The lock sleeve 1110 can comprisediametrically-opposed, inwardly-facing lock protrusions that, when thelock sleeve 1110 is in one position, are engagingly received withincorresponding portions of the drive notch 1316 in the intermediatefiring shaft portion 1310 and, when in another position, are notreceived within the drive notch 1316 to thereby permit relative axialmotion between the lock sleeve 1110 and the intermediate firing shaft1310. As can be further seen in FIG. 5, the lock sleeve 1110 furtherincludes a lock member 1112 that is sized to be movably received withina notch 1375 in a proximal end of the proximal articulation driver 1370.Such arrangement permits the lock sleeve 1110 to slightly rotate intoand out of engagement with the intermediate firing shaft portion 1310while remaining in position for engagement or in engagement with thenotch 1375 in the proximal articulation driver 1370. For example, whenthe lock sleeve 1110 is in its engaged position, the lock protrusionsare positioned within the drive notch 1316 in the intermediate firingshaft portion 1310 such that a distal pushing force and/or a proximalpulling force can be transmitted from the firing member assembly 1300 tothe lock sleeve 1110. Such axial pushing or pulling motion is thentransmitted from the lock sleeve 1110 to the proximal articulationdriver 1370 to thereby articulate the surgical end effector 1500. Ineffect, the firing member assembly 1300, the lock sleeve 1110, and theproximal articulation driver 1370 will move together when the locksleeve 1110 is in its engaged (articulation) position. On the otherhand, when the lock sleeve 1110 is in its disengaged position, the lockprotrusions are not received within the drive notch 1316 in theintermediate firing shaft portion 1310 and, as a result, a distalpushing force and/or a proximal pulling force may not be transmittedfrom the firing member assembly 1300 to the lock sleeve 1110 (and theproximal articulation driver 1370).

In the illustrated example, relative movement of the lock sleeve 1110between its engaged and disengaged positions may be controlled by theshifter assembly 1100 that interfaces with the proximal closure tube1910. Still referring to FIG. 5, the shifter assembly 1100 furtherincludes a shifter key 1120 that is configured to be slidably receivedwithin a key groove formed in the outer perimeter of the lock sleeve1110. Such arrangement enables the shifter key 1120 to move axially withrespect to the lock sleeve 1110. As discussed in further detail in U.S.patent application Ser. No. 15/635,631 entitled SURGICAL INSTRUMENT WITHAXIALLY MOVABLE CLOSURE MEMBER, filed on Jun. 28, 2017, the entiredisclosure of which is hereby incorporated by reference herein, aportion of the shifter key 1120 is configured to cammingly interact witha cam opening (not shown) in the proximal closure tube portion 1910.Also in the illustrated example, the shifter assembly 1100 furtherincludes a switch drum 1130 that is rotatably received on a proximal endportion of the proximal closure tube portion 1910. A portion of theshifter key 1120 extends through an axial slot segment in the switchdrum 1130 and is movably received within an arcuate slot segment in theswitch drum 1130. A switch drum torsion spring 1132 is mounted on theswitch drum 1130 and engages a portion of the nozzle assembly 1240 toapply a torsional bias or rotation which serves to rotate the switchdrum 1130 until the portion of the shifter key 1120 reaches an endportion of the cam opening in the proximal closure tube portion 1910.When in this position, the switch drum 1130 may provide a torsional biasto the shifter key 1120 which thereby causes the lock sleeve 1110 torotate into its engaged position with the intermediate firing shaftportion 1310. This position also corresponds to the unactuatedconfiguration of the proximal closure tube 1910 (and distal closure tubesegment 1930).

In one arrangement, for example, when the proximal closure tube 1910 isin an unactuated configuration (anvil 1810 is in an open position spacedaway from the cartridge mounted in the elongate channel 1602) actuationof the intermediate firing shaft portion 1310 will result in the axialmovement of the proximal articulation driver 1370 to facilitatearticulation of the end effector 1500. Once the user has articulated thesurgical end effector 1500 to a desired orientation, the user may thenactuate the proximal closure tube portion 1910. Actuation of theproximal closure tube portion 1910 will result in the distal travel ofthe distal closure tube segment 1930 to ultimately apply a closingmotion to the anvil 1810. This distal travel of the proximal closuretube portion 1910 will result in the cam opening therein camminglyinteracting with a cam portion of the shifter key 1120 to thereby causethe shifter key 1120 to rotate the lock sleeve 1110 in an actuationdirection. Such rotation of the lock sleeve 1110 will result in thedisengagement of the lock protrusions from the drive notch 1316 in theintermediate firing shaft portion 1310. When in such configuration, thefiring drive system 530 may be actuated to actuate the intermediatefiring shaft portion 1310 without actuating the proximal articulationdriver 1370. Further details concerning the operation of the switch drum1130 and lock sleeve 1110, as well as alternative articulation andfiring drive arrangements that may be employed with the variousinterchangeable surgical tool assemblies described herein, may be foundin U.S. patent application Ser. No. 13/803,086, now U.S. PatentApplication Publication No. 2014/0263541, and U.S. patent applicationSer. No. 15/019,196, the entire disclosures of which are herebyincorporated by reference herein.

As also illustrated in FIGS. 5 and 15, the interchangeable surgical toolassembly 1000 can comprise a slip ring assembly 1150 which can beconfigured to conduct electrical power to and/or from the surgical endeffector 1500 and/or communicate signals to and/or from the surgical endeffector 1500, back to an onboard circuit board 1152, while facilitatingrotational travel of the shaft and end effector 1500 about the shaftaxis SA relative to the tool chassis 1210 by rotating the nozzleassembly 1240. As shown in FIG. 15, in at least one arrangement, theonboard circuit board 1152 includes an onboard connector 1154 that isconfigured to interface with a housing connector 562 (FIG. 9)communicating with a microprocessor 560 that is supported in the handleassembly 500 or robotic system controller, for example. The slip ringassembly 1150 is configured to interface with a proximal connector 1153that interfaces with the onboard circuit board 1152. Further detailsconcerning the slip ring assembly 1150 and associated connectors may befound in U.S. patent application Ser. No. 13/803,086, now U.S. PatentApplication Publication No. 2014/0263541, and U.S. patent applicationSer. No. 15/019,196 which have each been herein incorporated byreference in their respective entirety as well as in U.S. patentapplication Ser. No. 13/800,067, entitled STAPLE CARTRIDGE TISSUETHICKNESS SENSOR SYSTEM, now U.S. Patent Application Publication No.2014/0263552, which is hereby incorporated by reference herein in itsentirety.

An example version of the interchangeable surgical tool assembly 1000disclosed herein may be employed in connection with a standard(mechanical) surgical fastener cartridge 1400 or a cartridge 1700 thatis configured to facilitate cutting of tissue with the knife member andseal the cut tissue using radio frequency (RF) energy. Turning again toFIG. 4, a conventional or standard mechanical-type cartridge 1400 isdepicted. Such cartridge arrangements are known and may comprise acartridge body 1402 that is sized and shaped to be removably receivedand supported in the elongate channel 1602. For example, the cartridgebody 1402 may be configured to be removably retained in snap engagementwith the elongate channel 1602. The cartridge body 1402 includes anelongate slot 1404 to accommodate axial travel of the knife member 1330therethrough. The cartridge body 1402 operably supports therein aplurality of staple drivers (not shown) that are aligned in rows on eachside of the centrally disposed elongate slot 1404. The drivers areassociated with corresponding staple/fastener pockets 1412 that openthrough the upper deck surface 1410 of the cartridge body 1402. Each ofthe staple drivers supports one or more surgical staple or fastener (notshown) thereon. A sled assembly 1420 is supported within a proximal endof the cartridge body 1402 and is located proximal to the drivers andfasteners in a starting position when the cartridge 1400 is new andunfired. The sled assembly 1420 includes a plurality of sloped orwedge-shaped cams 1422 wherein each cam 1422 corresponds to a particularline of fasteners or drivers located on a side of the slot 1404. Thesled assembly 1420 is configured to be contacted and driven by the knifemember 1330 as the knife member is driven distally through the tissuethat is clamped between the anvil and the cartridge deck surface 1410.As the drivers are driven upward toward the cartridge deck surface 1410,the fastener(s) supported thereon are driven out of their staple pockets1412 and through the tissue that is clamped between anvil and thecartridge.

Still referring to FIG. 4, the anvil 1810 in at least one form includesan anvil mounting portion 1820 that has a pair of anvil trunnions 1822protruding laterally therefrom to be pivotally received in correspondingtrunnion cradles 1614 formed in the upstanding walls 1622 of theproximal end portion 1610 of the elongate channel 1602. The anviltrunnions 1822 are pivotally retained in their corresponding trunnioncradle 1614 by the channel cap or anvil retainer 1630. The anvilmounting portion 1820 is movably or pivotably supported on the elongatechannel 1602 for selective pivotal travel relative thereto about a fixedanvil pivot axis that is transverse to the shaft axis SA. As shown inFIGS. 6 and 7, in at least one form, the anvil 1810 includes an anvilbody portion 1812 that is fabricated from an electrically conductivemetal material for example and has a staple forming undersurface 1813that has a series of fastener forming pockets 1814 formed therein oneach side of a centrally disposed anvil slot 1815 that is configured toslidably accommodate the knife member 1330 therein. The anvil slot 1815opens into an upper opening 1816 that extends longitudinally through theanvil body 1812 to accommodate the anvil engagement features 1336 on theknife member 1330 during firing. When a conventional mechanical surgicalstaple/fastener cartridge 1400 is installed in the elongate channel1602, the staples/fasteners are driven through the tissue T and intoforming contact with the corresponding fastener forming pockets 1814.The anvil body 1812 may have an opening in the upper portion thereof tofacilitate ease of installation for example. An anvil cap 1818 may beinserted therein and welded to the anvil body 1812 to enclose theopening and improve the overall stiffness of the anvil body 1812. Asshown in FIG. 7, to facilitate use of the end effector 1500 inconnection with RF cartridges 1700, the tissue facing segments 1817 ofthe fastener forming undersurface 1813 may have electrically insulativematerial 1819 thereon.

In the illustrated arrangement, the interchangeable surgical toolassembly 1000 is configured with a firing member lockout system,generally designated as 1640. See FIG. 8. As shown in FIG. 8, theelongate channel 1602 includes a bottom surface or bottom portion 1620that has two upstanding side walls 1622 protruding therefrom. Acentrally disposed longitudinal channel slot 1624 is formed through thebottom portion 1620 to facilitate the axial travel of the knife member1330 therethrough. The channel slot 1624 opens into a longitudinalpassage 1626 that accommodates the channel engagement feature or foot1338 on the knife member 1330. The passage 1626 serves to define twoinwardly extending ledge portions 1628 that serve to engagecorresponding portions of the channel engagement feature or foot 1338.The firing member lockout system 1640 includes proximal openings 1642located on each side of the channel slot 1624 that are each configuredto receive corresponding portions of the channel engagement feature orfoot 1338 when the knife member 1330 is in a starting position. A knifelockout spring 1650 is supported in the proximal end 1610 of theelongate channel 1602 and serves to bias the knife member 1330 downward.As shown in FIG. 8, the knife lockout spring 1650 includes two distallyending spring arms 1652 that are configured to engage correspondingcentral channel engagement features 1337 on the knife body 1332. Thespring arms 1652 are configured to bias the central channel engagementfeatures 1337 downward. Thus, when in the starting (unfired position),the knife member 1330 is biased downward such that the channelengagement features or foot 1338 is received within the correspondingproximal openings 1642 in the elongate 1602 channel. When in that lockedposition, if one were to attempt to distally advance the knife 1330, thecentral channel engagement features 1137 and/or foot 1338 would engageupstanding ledges 1654 on the elongate channel 1602 (FIGS. 8 and 11) andthe knife 1330 could not be fired.

Still referring to FIG. 8, the firing member lockout system 1640 alsoincludes an unlocking assembly 1660 formed or supported on a distal endof the firing member body 1332. The unlocking assembly 1660 includes adistally extending ledge 1662 that is configured to engage an unlockingfeature 1426 formed on the sled assembly 1420 when the sled assembly1420 is in its starting position in an unfired surgical staple cartridge1400. Thus, when an unfired surgical staple cartridge 1400 is properlyinstalled in the elongate channel 1602, the ledge 1662 on the unlockingassembly 1660 contacts the unlocking feature 1426 on the sled assembly1420 which serves to bias the knife member 1330 upward such that thecentral channel engagement features 1137 and/or foot 1338 clear theupstanding ledges 1654 in the channel bottom 1620 to facilitate axialpassage of the knife member 1330 through the elongate channel 1602. If apartially fired cartridge 1400 is unwittingly installed in the elongatechannel, the sled assembly 1420 will not be in the starting position andthe knife member 1330 will remain in the locked position.

Attachment of the interchangeable surgical tool assembly 1000 to thehandle assembly 500 will now be described with reference to FIGS. 3 and9. To commence the coupling process, the clinician may position the toolchassis 1210 of the interchangeable surgical tool assembly 1000 above oradjacent to the distal end of the handle frame 506 such that taperedattachment portions 1212 formed on the tool chassis 1210 are alignedwith dovetail slots 507 in the handle frame 506. The clinician may thenmove the surgical tool assembly 1000 along an installation axis IA thatis perpendicular to the shaft axis SA to seat the tapered attachmentportions 1212 in “operable engagement” with the corresponding dovetailreceiving slots 507 in the distal end of the handle frame 506. In doingso, the firing shaft attachment lug 1314 on the intermediate firingshaft portion 1310 will also be seated in the cradle 544 in thelongitudinally movable drive member 540 within the handle assembly 500and the portions of a pin 516 on a closure link 514 will be seated inthe corresponding hooks 1917 in the closure shuttle 1914. As usedherein, the term “operable engagement” in the context of two componentsmeans that the two components are sufficiently engaged with each otherso that upon application of an actuation motion thereto, the componentsmay carry out their intended action, function and/or procedure. Alsoduring this process, the onboard connector 1154 on the surgical toolassembly 1000 is coupled to the housing connector 562 that communicateswith the microprocessor 560 that is supported in the handle assembly 500or robotic system controller, for example.

During a typical surgical procedure, the clinician may introduce thesurgical end effector 1500 into the surgical site through a trocar orother opening in the patient to access the target tissue. When doing so,the clinician typically axially aligns the surgical end effector 1500along the shaft axis SA (unarticulated state). Once the surgical endeffector 1500 has passed through the trocar port, for example, theclinician may need to articulate the end effector 1500 to advantageouslyposition it adjacent the target tissue. This is prior to closing theanvil 1810 onto the target tissue, so the closure drive system 510 wouldremain unactuated. When in this position, actuation of the firing drivesystem 530 will result in the application of articulation motions to theproximal articulation driver 1370. Once the end effector 1500 hasattained the desired articulated position, the firing drive system 530is deactivated and the articulation lock 1390 may retain the surgicalend effector 1500 in the articulated position. The clinician may thenactuate the closure drive system 510 to close the anvil 1810 onto thetarget tissue. Such actuation of the closure drive system 510 may alsoresult in the shifter assembly 1100 delinking the proximal articulationdriver 1370 from the intermediate firing shaft portion 1310. Thus, oncethe target tissue has been captured in the surgical end effector 1500,the clinician may once again actuate the firing drive system 530 toaxially advance the firing member 1330 through the surgicalstaple/fastener cartridge 1400 or RF cartridge 1700 to cut the clampedtissue and fire the staples/fasteners into the cut tissue T. Otherclosure and firing drive arrangements, actuator arrangements (bothhandheld, manual and automated or robotic) may also be employed tocontrol the axial movement of the closure system components, thearticulation system components and/or the firing system components ofthe surgical tool assembly 1000 without departing from the scope of thepresent disclosure.

As indicated above, the surgical tool assembly 1000 is configured to beused in connection with conventional mechanical surgical staple/fastenercartridges 1400 as well as with RF cartridges 1700. In at least oneform, the RF cartridge 1700 may facilitate mechanical cutting of tissuethat is clamped between the anvil 1810 and the RF cartridge 1700 withthe knife member 1330 while coagulating electrical current is deliveredto the tissue in the current path. Alternative arrangements formechanically cutting and coagulating tissue using electrical current aredisclosed in, for example, U.S. Pat. Nos. 5,403,312; 7,780,663 and U.S.patent application Ser. No. 15/142,609, entitled ELECTROSURGICALINSTRUMENT WITH ELECTRICALLY CONDUCTIVE GAP SETTING AND TISSUE ENGAGINGMEMBERS, the entire disclosures of each said references beingincorporated by reference herein. Such instruments, may, for example,improve hemostasis, reduce surgical complexity as well as operating roomtime.

As shown in FIGS. 10-12, in at least one arrangement, the RF surgicalcartridge 1700 includes a cartridge body 1710 that is sized and shapedto be removably received and supported in the elongate channel 1602. Forexample, the cartridge body 1710 may be configured to be removablyretained in snap engagement with the elongate channel 1602. In variousarrangements, the cartridge body 1710 may be fabricated from a polymermaterial, such as, for example, an engineering thermoplastic such as theliquid crystal polymer (LCP) VECTRA™ and the elongate channel 1602 maybe fabricated from metal. In at least one aspect, the cartridge body1710 includes a centrally disposed elongate slot 1712 that extendslongitudinally through the cartridge body to accommodate longitudinaltravel of the knife 1330 therethrough. As shown in FIGS. 10 and 11, apair of lockout engagement tails 1714 extend proximally from thecartridge body 1710. Each lockout engagement tail 1714 has a lockout pad1716 formed on the underside thereof that are sized to be receivedwithin a corresponding proximal opening portion 1642 in the channelbottom 1620. Thus, when the cartridge 1700 is properly installed in theelongate channel 1602, the lockout engagement tails 1714 cover theopenings 1642 and ledges 1654 to retain the knife 1330 in an unlockedposition ready for firing.

Turning now to FIGS. 10-13, in the illustrated example, the cartridgebody 1710 is formed with a centrally disposed raised electrode pad 1720.As can be most particularly seen in FIG. 6, the elongate slot 1712extends through the center of the electrode pad 1720 and serves todivide the pad 1720 into a left pad segment 1720L and a right padsegment 1720R. A right flexible circuit assembly 1730R is attached tothe right pad segment 1720R and a left flexible circuit assembly 1730Lis attached to the left pad segment 1720L. In at least one arrangementfor example, the right flexible circuit 1730R comprises a plurality ofelectrical conductors 1732R that may include, for example, widerelectrical conductors/conductors for RF purposes and thinner electricalconductors for conventional stapling purposes that are supported orattached or embedded into a right insulator sheath/member 1734R that isattached to the right pad 1720R. In addition, the right flexible circuitassembly 1730R includes a “phase one”, proximal right electrode 1736Rand a “phase two” distal right electrode 1738R. Likewise, the leftflexible circuit assembly 1730L comprises a plurality of electricalconductors 1732L that may include, for example, wider electricalconductors/conductors for RF purposes and thinner electrical conductorsfor conventional stapling purposes that are supported or attached orembedded into a left insulator sheath/member 1734L that is attached tothe left pad 1720L. In addition, the left flexible circuit assembly1730L includes a “phase one”, proximal left electrode 1736L and a “phasetwo” distal left electrode 1738L. The left and right electricalconductors 1732L, 1732R are attached to a distal micro-chip 1740 mountedto the distal end portion of the cartridge body 1710. In onearrangement, for example, each of the right and left flexible circuits1730R, 1730L may have an overall width “CW” of approximately 0.025inches and each of the electrodes 1736R, 1736L, 1738R, 1738R has a width“EW” of approximately 0.010 inches for example. See FIG. 13. However,other widths/sizes are contemplated and may be employed in alternativeaspects.

In at least one arrangement, RF energy is supplied to the surgical toolassembly 1000 by a conventional RF generator 400 through a supply lead402. In at least one arrangement, the supply lead 402 includes a maleplug assembly 406 that is configured to be plugged into correspondingfemale connectors 410 that are attached to a segmented RF circuit 1160on the an onboard circuit board 1152. See FIG. 15. Such arrangementfacilitates rotational travel of the shaft and end effector 1500 aboutthe shaft axis SA relative to the tool chassis 1210 by rotating thenozzle assembly 1240 without winding up the supply lead 402 from thegenerator 400. An onboard on/off power switch 420 is supported on thelatch assembly 1280 and tool chassis 1210 for turning the RF generatoron and off. When the tool assembly 1000 is operably coupled to thehandle assembly 500 or robotic system, the onboard segmented RF circuit1160 communicates with the microprocessor 560 through the connectors1154 and 562. As shown in FIG. 1, the handle assembly 500 may alsoinclude a display screen 430 for viewing information about the progressof sealing, stapling, knife location, status of the cartridge, tissue,temperature, etc. As can also be seen FIG. 15, the slip ring assembly1150 interfaces with a distal connector 1162 that includes a flexibleshaft circuit strip or assembly 1164 that may include a plurality ofnarrow electrical conductors 1166 for stapling related activities andwider electrical conductors 1168 used for RF purposes. As shown in FIGS.14 and 15, the flexible shaft circuit strip 1164 is centrally supportedbetween the laminated plates or bars 1322 that form the knife bar 1320.Such arrangement facilitates sufficient flexing of the knife bar 1320and flexible shaft circuit strip 1164 during articulation of the endeffector 1500 while remaining sufficiently stiff so as to enable theknife member 1330 to be distally advanced through the clamped tissue.

Turning again to FIG. 10, in at least one illustrated arrangement, theelongate channel 1602 includes a channel circuit 1670 supported in arecess 1621 that extends from the proximal end 1610 of the elongatechannel 1602 to a distal location 1623 in the elongate channel bottomportion 1620. The channel circuit 1670 includes a proximal contactportion 1672 that contacts a distal contact portion 1169 of the flexibleshaft circuit strip 1164 for electrical contact therewith. A distal end1674 of the channel circuit 1670 is received within a corresponding wallrecess 1625 formed in one of the channel walls 1622 and is folded overand attached to an upper edge 1627 of the channel wall 1622. A series ofcorresponding exposed contacts 1676 are provided in the distal end 1674of the channel circuit 1670 As shown in FIG. 10. As can also be seen inFIG. 10, an end 1752 of a flexible cartridge circuit 1750 is attached tothe distal micro-chip 1740 and is affixed to the distal end portion ofthe cartridge body 1710. Another end 1754 is folded over the edge of thecartridge deck surface 1711 and includes exposed contacts 1756configured to make electrical contact with the exposed contacts 1676 ofthe channel circuit 1670. Thus, when the RF cartridge 1700 is installedin the elongate channel 1602, the electrodes as well as the distalmicro-chip 1740 are powered and communicate with the onboard circuitboard 1152 through contact between the flexible cartridge circuit 1750,the flexible channel circuit 1670, the flexible shaft circuit 1164 andthe slip ring assembly 1150.

FIGS. 16A-16B is a block diagram of a control circuit 700 of thesurgical instrument 10 of FIG. 1 spanning two drawing sheets accordingto one aspect of this disclosure. Referring primarily to FIGS. 16A-16B,a handle assembly 702 may include a motor 714 which can be controlled bya motor driver 715 and can be employed by the firing system of thesurgical instrument 10. In various forms, the motor 714 may be a DCbrushed driving motor having a maximum rotational speed of approximately25,000 RPM. In other arrangements, the motor 714 may include a brushlessmotor, a cordless motor, a synchronous motor, a stepper motor, or anyother suitable electric motor. The motor driver 715 may comprise anH-Bridge driver comprising field-effect transistors (FETs) 719, forexample. The motor 714 can be powered by the power assembly 706releasably mounted to the handle assembly 500 for supplying controlpower to the surgical instrument 10. The power assembly 706 may comprisea battery which may include a number of battery cells connected inseries that can be used as the power source to power the surgicalinstrument 10. In certain circumstances, the battery cells of the powerassembly 706 may be replaceable and/or rechargeable. In at least oneexample, the battery cells can be Lithium-Ion batteries which can beseparably couplable to the power assembly 706.

The shaft assembly 704 may include a shaft assembly controller 722 whichcan communicate with a safety controller and power management controller716 through an interface while the shaft assembly 704 and the powerassembly 706 are coupled to the handle assembly 702. For example, theinterface may comprise a first interface portion 725 which may includeone or more electric connectors for coupling engagement withcorresponding shaft assembly electric connectors and a second interfaceportion 727 which may include one or more electric connectors forcoupling engagement with corresponding power assembly electricconnectors to permit electrical communication between the shaft assemblycontroller 722 and the power management controller 716 while the shaftassembly 704 and the power assembly 706 are coupled to the handleassembly 702. One or more communication signals can be transmittedthrough the interface to communicate one or more of the powerrequirements of the attached interchangeable shaft assembly 704 to thepower management controller 716. In response, the power managementcontroller may modulate the power output of the battery of the powerassembly 706, as described below in greater detail, in accordance withthe power requirements of the attached shaft assembly 704. Theconnectors may comprise switches which can be activated after mechanicalcoupling engagement of the handle assembly 702 to the shaft assembly 704and/or to the power assembly 706 to allow electrical communicationbetween the shaft assembly controller 722 and the power managementcontroller 716.

The interface can facilitate transmission of the one or morecommunication signals between the power management controller 716 andthe shaft assembly controller 722 by routing such communication signalsthrough a main controller 717 residing in the handle assembly 702, forexample. In other circumstances, the interface can facilitate a directline of communication between the power management controller 716 andthe shaft assembly controller 722 through the handle assembly 702 whilethe shaft assembly 704 and the power assembly 706 are coupled to thehandle assembly 702.

The main controller 717 may be any single core or multicore processorsuch as those known under the trade name ARM Cortex by TexasInstruments. In one aspect, the main controller 717 may be anLM4F230H5QR ARM Cortex-M4F Processor Core, available from TexasInstruments, for example, comprising on-chip memory of 256 KBsingle-cycle flash memory, or other non-volatile memory, up to 40 MHz, aprefetch buffer to improve performance above 40 MHz, a 32 KBsingle-cycle serial random access memory (SRAM), internal read-onlymemory (ROM) loaded with StellarisWare® software, 2 KB electricallyerasable programmable read-only memory (EEPROM), one or more pulse widthmodulation (PWM) modules, one or more quadrature encoder inputs (QEI)analog, one or more 12-bit Analog-to-Digital Converters (ADC) with 12analog input channels, details of which are available for the productdatasheet.

The safety controller may be a safety controller platform comprising twocontroller-based families such as TMS570 and RM4x known under the tradename Hercules ARM Cortex R4, also by Texas Instruments. The safetycontroller may be configured specifically for IEC 61508 and ISO 26262safety critical applications, among others, to provide advancedintegrated safety features while delivering scalable performance,connectivity, and memory options.

The power assembly 706 may include a power management circuit which maycomprise the power management controller 716, a power modulator 738, anda current sense circuit 736. The power management circuit can beconfigured to modulate power output of the battery based on the powerrequirements of the shaft assembly 704 while the shaft assembly 704 andthe power assembly 706 are coupled to the handle assembly 702. The powermanagement controller 716 can be programmed to control the powermodulator 738 of the power output of the power assembly 706 and thecurrent sense circuit 736 can be employed to monitor power output of thepower assembly 706 to provide feedback to the power managementcontroller 716 about the power output of the battery so that the powermanagement controller 716 may adjust the power output of the powerassembly 706 to maintain a desired output. The power managementcontroller 716 and/or the shaft assembly controller 722 each maycomprise one or more processors and/or memory units which may store anumber of software modules.

The surgical instrument 10 (FIGS. 1-5) may comprise an output device 742which may include devices for providing a sensory feedback to a user.Such devices may comprise, for example, visual feedback devices (e.g.,an LCD display screen, LED indicators), audio feedback devices (e.g., aspeaker, a buzzer) or tactile feedback devices (e.g., haptic actuators).In certain circumstances, the output device 742 may comprise a display743 which may be included in the handle assembly 702. The shaft assemblycontroller 722 and/or the power management controller 716 can providefeedback to a user of the surgical instrument 10 through the outputdevice 742. The interface can be configured to connect the shaftassembly controller 722 and/or the power management controller 716 tothe output device 742. The output device 742 can instead be integratedwith the power assembly 706. In such circumstances, communicationbetween the output device 742 and the shaft assembly controller 722 maybe accomplished through the interface while the shaft assembly 704 iscoupled to the handle assembly 702.

The control circuit 700 comprises circuit segments configured to controloperations of the powered surgical instrument 10. A safety controllersegment (Segment 1) comprises a safety controller and the maincontroller 717 segment (Segment 2). The safety controller and/or themain controller 717 are configured to interact with one or moreadditional circuit segments such as an acceleration segment, a displaysegment, a shaft segment, an encoder segment, a motor segment, and apower segment. Each of the circuit segments may be coupled to the safetycontroller and/or the main controller 717. The main controller 717 isalso coupled to a flash memory. The main controller 717 also comprises aserial communication interface. The main controller 717 comprises aplurality of inputs coupled to, for example, one or more circuitsegments, a battery, and/or a plurality of switches. The segmentedcircuit may be implemented by any suitable circuit, such as, forexample, a printed circuit board assembly (PCBA) within the poweredsurgical instrument 10. It should be understood that the term processoras used herein includes any microprocessor, processors, controller,controllers, or other basic computing device that incorporates thefunctions of a computer's central processing unit (CPU) on an integratedcircuit or at most a few integrated circuits. The main controller 717 isa multipurpose, programmable device that accepts digital data as input,processes it according to instructions stored in its memory, andprovides results as output. It is an example of sequential digitallogic, as it has internal memory. The control circuit 700 can beconfigured to implement one or more of the processes described herein.

The acceleration segment (Segment 3) comprises an accelerometer. Theaccelerometer is configured to detect movement or acceleration of thepowered surgical instrument 10. Input from the accelerometer may be usedto transition to and from a sleep mode, identify an orientation of thepowered surgical instrument, and/or identify when the surgicalinstrument has been dropped. In some examples, the acceleration segmentis coupled to the safety controller and/or the main controller 717.

The display segment (Segment 4) comprises a display connector coupled tothe main controller 717. The display connector couples the maincontroller 717 to a display through one or more integrated circuitdrivers of the display. The integrated circuit drivers of the displaymay be integrated with the display and/or may be located separately fromthe display. The display may comprise any suitable display, such as, forexample, an organic light-emitting diode (OLED) display, aliquid-crystal display (LCD), and/or any other suitable display. In someexamples, the display segment is coupled to the safety controller.

The shaft segment (Segment 5) comprises controls for an interchangeableshaft assembly 500 coupled to the surgical instrument 10 (FIGS. 1-5)and/or one or more controls for an end effector 1500 coupled to theinterchangeable shaft assembly 500. The shaft segment comprises a shaftconnector configured to couple the main controller 717 to a shaft PCBA.The shaft PCBA comprises a low-power microcontroller with aferroelectric random access memory (FRAM), an articulation switch, ashaft release Hall effect switch, and a shaft PCBA EEPROM. The shaftPCBA EEPROM comprises one or more parameters, routines, and/or programsspecific to the interchangeable shaft assembly 500 and/or the shaftPCBA. The shaft PCBA may be coupled to the interchangeable shaftassembly 500 and/or integral with the surgical instrument 10. In someexamples, the shaft segment comprises a second shaft EEPROM. The secondshaft EEPROM comprises a plurality of algorithms, routines, parameters,and/or other data corresponding to one or more shaft assemblies 500and/or end effectors 1500 that may be interfaced with the poweredsurgical instrument 10.

The position encoder segment (Segment 6) comprises one or more magneticangle rotary position encoders. The one or more magnetic angle rotaryposition encoders are configured to identify the rotational position ofthe motor 714, an interchangeable shaft assembly 500, and/or an endeffector 1500 of the surgical instrument 10 (FIGS. 1-5). In someexamples, the magnetic angle rotary position encoders may be coupled tothe safety controller and/or the main controller 717.

The motor circuit segment (Segment 7) comprises a motor 714 configuredto control movements of the powered surgical instrument 10 (FIGS. 1-5).The motor 714 is coupled to the main microcontroller processor 717 by anH-bridge driver comprising one or more H-bridge field-effect transistors(FETs) and a motor controller. The H-bridge driver is also coupled tothe safety controller. A motor current sensor is coupled in series withthe motor to measure the current draw of the motor. The motor currentsensor is in signal communication with the main controller 717 and/orthe safety controller. In some examples, the motor 714 is coupled to amotor electromagnetic interference (EMI) filter.

The motor controller controls a first motor flag and a second motor flagto indicate the status and position of the motor 714 to the maincontroller 717. The main controller 717 provides a pulse-widthmodulation (PWM) high signal, a PWM low signal, a direction signal, asynchronize signal, and a motor reset signal to the motor controllerthrough a buffer. The power segment is configured to provide a segmentvoltage to each of the circuit segments.

The power segment (Segment 8) comprises a battery coupled to the safetycontroller, the main controller 717, and additional circuit segments.The battery is coupled to the segmented circuit by a battery connectorand a current sensor. The current sensor is configured to measure thetotal current draw of the segmented circuit. In some examples, one ormore voltage converters are configured to provide predetermined voltagevalues to one or more circuit segments. For example, in some examples,the segmented circuit may comprise 3.3V voltage converters and/or 5Vvoltage converters. A boost converter is configured to provide a boostvoltage up to a predetermined amount, such as, for example, up to 13V.The boost converter is configured to provide additional voltage and/orcurrent during power intensive operations and prevent brownout orlow-power conditions.

A plurality of switches are coupled to the safety controller and/or themain controller 717. The switches may be configured to controloperations of the surgical instrument 10 (FIGS. 1-5), of the segmentedcircuit, and/or indicate a status of the surgical instrument 10. Abail-out door switch and Hall effect switch for bailout are configuredto indicate the status of a bail-out door. A plurality of articulationswitches, such as, for example, a left side articulation left switch, aleft side articulation right switch, a left side articulation centerswitch, a right side articulation left switch, a right side articulationright switch, and a right side articulation center switch are configuredto control articulation of an interchangeable shaft assembly 500 (FIGS.1 and 3) and/or the end effector 300 (FIGS. 1 and 4). A left sidereverse switch and a right side reverse switch are coupled to the maincontroller 717. The left side switches comprising the left sidearticulation left switch, the left side articulation right switch, theleft side articulation center switch, and the left side reverse switchare coupled to the main controller 717 by a left flex connector. Theright side switches comprising the right side articulation left switch,the right side articulation right switch, the right side articulationcenter switch, and the right side reverse switch are coupled to the maincontroller 717 by a right flex connector. A firing switch, a clamprelease switch, and a shaft engaged switch are coupled to the maincontroller 717.

Any suitable mechanical, electromechanical, or solid state switches maybe employed to implement the plurality of switches, in any combination.For example, the switches may be limit switches operated by the motionof components associated with the surgical instrument 10 (FIGS. 1-5) orthe presence of an object. Such switches may be employed to controlvarious functions associated with the surgical instrument 10. A limitswitch is an electromechanical device that consists of an actuatormechanically linked to a set of contacts. When an object comes intocontact with the actuator, the device operates the contacts to make orbreak an electrical connection. Limit switches are used in a variety ofapplications and environments because of their ruggedness, ease ofinstallation, and reliability of operation. They can determine thepresence or absence, passing, positioning, and end of travel of anobject. In other implementations, the switches may be solid stateswitches that operate under the influence of a magnetic field such asHall-effect devices, magneto-resistive (MR) devices, giantmagneto-resistive (GMR) devices, magnetometers, among others. In otherimplementations, the switches may be solid state switches that operateunder the influence of light, such as optical sensors, infrared sensors,ultraviolet sensors, among others. Still, the switches may be solidstate devices such as transistors (e.g., FET, Junction-FET, metal-oxidesemiconductor-FET (MOSFET), bipolar, and the like). Other switches mayinclude electrical conductorless switches, ultrasonic switches,accelerometers, inertial sensors, among others.

FIG. 17 is another block diagram of the control circuit 700 of thesurgical instrument of FIG. 1 illustrating interfaces between the handleassembly 702 and the power assembly 706 and between the handle assembly702 and the interchangeable shaft assembly 704 according to one aspectof this disclosure. The handle assembly 702 may comprise a maincontroller 717, a shaft assembly connector 726 and a power assemblyconnector 730. The power assembly 706 may include a power assemblyconnector 732, a power management circuit 734 that may comprise thepower management controller 716, a power modulator 738, and a currentsense circuit 736. The shaft assembly connectors 730, 732 form aninterface 727. The power management circuit 734 can be configured tomodulate power output of the battery 707 based on the power requirementsof the interchangeable shaft assembly 704 while the interchangeableshaft assembly 704 and the power assembly 706 are coupled to the handleassembly 702. The power management controller 716 can be programmed tocontrol the power modulator 738 of the power output of the powerassembly 706 and the current sense circuit 736 can be employed tomonitor power output of the power assembly 706 to provide feedback tothe power management controller 716 about the power output of thebattery 707 so that the power management controller 716 may adjust thepower output of the power assembly 706 to maintain a desired output. Theshaft assembly 704 comprises a shaft processor 719 coupled to anon-volatile memory 721 and shaft assembly connector 728 to electricallycouple the shaft assembly 704 to the handle assembly 702. The shaftassembly connectors 726, 728 form interface 725. The main controller717, the shaft processor 719, and/or the power management controller 716can be configured to implement one or more of the processes describedherein.

The surgical instrument 10 (FIGS. 1-5) may comprise an output device 742to a sensory feedback to a user. Such devices may comprise visualfeedback devices (e.g., an LCD display screen, LED indicators), audiofeedback devices (e.g., a speaker, a buzzer), or tactile feedbackdevices (e.g., haptic actuators). In certain circumstances, the outputdevice 742 may comprise a display 743 that may be included in the handleassembly 702. The shaft assembly controller 722 and/or the powermanagement controller 716 can provide feedback to a user of the surgicalinstrument 10 through the output device 742. The interface 727 can beconfigured to connect the shaft assembly controller 722 and/or the powermanagement controller 716 to the output device 742. The output device742 can be integrated with the power assembly 706. Communication betweenthe output device 742 and the shaft assembly controller 722 may beaccomplished through the interface 725 while the interchangeable shaftassembly 704 is coupled to the handle assembly 702. Having described acontrol circuit 700 (FIGS. 16A-16B and 6) for controlling the operationof the surgical instrument 10 (FIGS. 1-5), the disclosure now turns tovarious configurations of the surgical instrument 10 (FIGS. 1-5) andcontrol circuit 700.

FIG. 18 is a schematic diagram of a surgical instrument 600 configuredto control various functions according to one aspect of this disclosure.In one aspect, the surgical instrument 600 is programmed to controldistal translation of a displacement member such as the I-beam 614. Thesurgical instrument 600 comprises an end effector 602 that may comprisean anvil 616, an I-beam 614, and a removable staple cartridge 618 whichmay be interchanged with an RF cartridge 609 (shown in dashed line). Theend effector 602, anvil 616, I-beam 614, staple cartridge 618, and RFcartridge 609 may be configured as described herein, for example, withrespect to FIGS. 1-15. For conciseness and clarity of disclosure,several aspects of the present disclosure may be described withreference to FIG. 18. It will be appreciated that the components shownschematically in FIG. 18 such as the control circuit 610, sensors 638,position sensor 634, end effector 602, I-beam 614, staple cartridge 618,RF cartridge 609, anvil 616, are described in connection with FIGS. 1-17of this disclosure.

Accordingly, the components represented schematically in FIG. 18 may bereadily substituted with the physical and functional equivalentcomponents described in connection with FIGS. 1-17. For example, in oneaspect, the control circuit 610 may be implemented as the controlcircuit 700 shown and described in connection with FIGS. 16-17. In oneaspect, the sensors 638 may be implemented as a limit switch,electromechanical device, solid state switches, Hall-effect devices,magneto-resistive (MR) devices, giant magneto-resistive (GMR) devices,magnetometers, among others. In other implementations, the sensors 638may be solid state switches that operate under the influence of light,such as optical sensors, infrared sensors, ultraviolet sensors, amongothers. Still, the switches may be solid state devices such astransistors (e.g., FET, Junction-FET, metal-oxide semiconductor-FET(MOSFET), bipolar, and the like). In other implementations, the sensors638 may include electrical conductorless switches, ultrasonic switches,accelerometers, inertial sensors, among others. In one aspect, theposition sensor 634 may be implemented as an absolute positioning systemcomprising a magnetic rotary absolute positioning system implemented asan AS5055EQFT single-chip magnetic rotary position sensor available fromAustria Microsystems, AG. The position sensor 634 may interface with thecontrol circuit 700 to provide an absolute positioning system. Theposition may include multiple Hall-effect elements located above amagnet and coupled to a CORDIC processor (for Coordinate RotationDigital Computer), also known as the digit-by-digit method and Volder'salgorithm, is provided to implement a simple and efficient algorithm tocalculate hyperbolic and trigonometric functions that require onlyaddition, subtraction, bitshift, and table lookup operations. In oneaspect, the end effector 602 may be implemented as surgical end effector1500 shown and described in connection with FIGS. 1, 2, and 4. In oneaspect, the I-beam 614 may be implemented as the knife member 1330comprising a knife body 1332 that operably supports a tissue cuttingblade 1334 thereon and may further include anvil engagement tabs orfeatures 1336 and channel engagement features or a foot 1338 as shownand described in connection with FIGS. 2-4, 8, 11 and 14. In one aspect,the staple cartridge 618 may be implemented as the standard (mechanical)surgical fastener cartridge 1400 shown and described in connection withFIG. 4. In one aspect, the RF cartridge 609 may be implemented as theradio frequency (RF) cartridge 1700 shown and described in connectionwith FIGS. 1, 2, 6, and 10-13. In one aspect, the anvil 616 may beimplemented the anvil 1810 shown and described in connection with FIGS.1, 2, 4, and 6. These and other sensors arrangements are described incommonly owned U.S. patent application Ser. No. 15/628,175, entitledTECHNIQUES FOR ADAPTIVE CONTROL OF MOTOR VELOCITY OF A SURGICAL STAPLINGAND CUTTING INSTRUMENT, which is incorporated herein by reference in itsentirety.

The position, movement, displacement, and/or translation of a linerdisplacement member, such as the I-beam 614, can be measured by anabsolute positioning system, sensor arrangement, and position sensorrepresented as position sensor 634. Because the I-beam 614 is coupled tothe longitudinally movable drive member 540, the position of the I-beam614 can be determined by measuring the position of the longitudinallymovable drive member 540 employing the position sensor 634. Accordingly,in the following description, the position, displacement, and/ortranslation of the I-beam 614 can be achieved by the position sensor 634as described herein. A control circuit 610, such as the control circuit700 described in FIGS. 16A and 16B, may be programmed to control thetranslation of the displacement member, such as the I-beam 614, asdescribed herein. The control circuit 610, in some examples, maycomprise one or more microcontrollers, microprocessors, or othersuitable processors for executing instructions that cause the processoror processors to control the displacement member, e.g., the I-beam 614,in the manner described. In one aspect, a timer/counter circuit 631provides an output signal, such as elapsed time or a digital count, tothe control circuit 610 to correlate the position of the I-beam 614 asdetermined by the position sensor 634 with the output of thetimer/counter circuit 631 such that the control circuit 610 candetermine the position of the I-beam 614 at a specific time (t) relativeto a starting position. The timer/counter circuit 631 may be configuredto measure elapsed time, count external evens, or time external events.

The control circuit 610 may generate a motor set point signal 622. Themotor set point signal 622 may be provided to a motor controller 608.The motor controller 608 may comprise one or more circuits configured toprovide a motor drive signal 624 to the motor 604 to drive the motor 604as described herein. In some examples, the motor 604 may be a brushed DCelectric motor, such as the motor 505 shown in FIG. 1. For example, thevelocity of the motor 604 may be proportional to the motor drive signal624. In some examples, the motor 604 may be a brushless direct current(DC) electric motor and the motor drive signal 624 may comprise apulse-width-modulated (PWM) signal provided to one or more statorwindings of the motor 604. Also, in some examples, the motor controller608 may be omitted and the control circuit 610 may generate the motordrive signal 624 directly.

The motor 604 may receive power from an energy source 612. The energysource 612 may be or include a battery, a super capacitor, or any othersuitable energy source 612. The motor 604 may be mechanically coupled tothe I-beam 614 via a transmission 606. The transmission 606 may includeone or more gears or other linkage components to couple the motor 604 tothe I-beam 614. A position sensor 634 may sense a position of the I-beam614. The position sensor 634 may be or include any type of sensor thatis capable of generating position data that indicates a position of theI-beam 614. In some examples, the position sensor 634 may include anencoder configured to provide a series of pulses to the control circuit610 as the I-beam 614 translates distally and proximally. The controlcircuit 610 may track the pulses to determine the position of the I-beam614. Other suitable position sensor may be used, including, for example,a proximity sensor. Other types of position sensors may provide othersignals indicating motion of the I-beam 614. Also, in some examples, theposition sensor 634 may be omitted. Where the motor 604 is a steppermotor, the control circuit 610 may track the position of the I-beam 614by aggregating the number and direction of steps that the motor 604 hasbeen instructed to execute. The position sensor 634 may be located inthe end effector 602 or at any other portion of the instrument.

The control circuit 610 may be in communication with one or more sensors638. The sensors 638 may be positioned on the end effector 602 andadapted to operate with the surgical instrument 600 to measure thevarious derived parameters such as gap distance versus time, tissuecompression versus time, and anvil strain versus time. The sensors 638may comprise a magnetic sensor, a magnetic field sensor, a strain gauge,a pressure sensor, a force sensor, an inductive sensor such as an eddycurrent sensor, a resistive sensor, a capacitive sensor, an opticalsensor, and/or any other suitable sensor for measuring one or moreparameters of the end effector 602. The sensors 638 may include one ormore sensors.

The one or more sensors 638 may comprise a strain gauge, such as amicro-strain gauge, configured to measure the magnitude of the strain inthe anvil 616 during a clamped condition. The strain gauge provides anelectrical signal whose amplitude varies with the magnitude of thestrain. The sensors 638 may comprise a pressure sensor configured todetect a pressure generated by the presence of compressed tissue betweenthe anvil 616 and the staple cartridge 618. The sensors 638 may beconfigured to detect impedance of a tissue section located between theanvil 616 and the staple cartridge 618 that is indicative of thethickness and/or fullness of tissue located therebetween.

The sensors 638 may be is configured to measure forces exerted on theanvil 616 by the closure drive system. For example, one or more sensors638 can be at an interaction point between the closure tube 1910 (FIGS.1-4) and the anvil 616 to detect the closure forces applied by theclosure tube 1910 to the anvil 616. The forces exerted on the anvil 616can be representative of the tissue compression experienced by thetissue section captured between the anvil 616 and the staple cartridge618. The one or more sensors 638 can be positioned at variousinteraction points along the closure drive system to detect the closureforces applied to the anvil 616 by the closure drive system. The one ormore sensors 638 may be sampled in real time during a clamping operationby a processor as described in FIGS. 16A-16B. The control circuit 610receives real-time sample measurements to provide analyze time basedinformation and assess, in real time, closure forces applied to theanvil 616.

A current sensor 636 can be employed to measure the current drawn by themotor 604. The force required to advance the I-beam 614 corresponds tothe current drawn by the motor 604. The force is converted to a digitalsignal and provided to the control circuit 610.

The RF energy source 400 is coupled to the end effector 602 and isapplied to the RF cartridge 609 when the RF cartridge 609 is loaded inthe end effector 602 in place of the staple cartridge 618. The controlcircuit 610 controls the delivery of the RF energy to the RF cartridge609.

Systems and Methods of Displaying Surgical Instrument Status

In a surgical sealing and stapling instrument, it may be useful todisplay a variety of information captured by the sensors of the surgicalinstrument to the operator so that the operator can ensure that theinstrument is functioning properly or take corrective action ifunexpected tissue conditions are being encountered or if the instrumentis not functioning properly.

In various aspects, the surgical instrument can include one or moresensors that are configured to measure a variety of different parametersassociated with the operation of the surgical instrument. Suchparameters can include the status of the RF energy applied by thesurgical instrument, the temperature of the tissue being sealed by thesurgical instrument, the water content of the tissue, the operationalstatus of the surgical instrument, and the thickness of the clampedtissue. The surgical instrument can be configured to monitor thesevarious parameters and present information associated with them to theoperator of the instrument via, for example, the display 430 (FIG. 1).In various aspects, the display 430 can present the monitored parametersto the operator via a graphical display.

In some aspects, the surgical instrument can include a sensor or sensorassembly configured to detect the position of the closure trigger, i.e.,whether the closure trigger is actuated. One such aspect is depicted inFIGS. 19-20, which are side elevational views of the surgical instrument2000 with the casing removed, wherein the closure trigger 2002 isalternatively in the actuated and unactuated positions, in accordancewith one or more aspects of the present disclosure. As described in moredetail above, the unactuated position of the closure trigger 2002 isassociated with an open or unclamped position for the end effector 1500(FIG. 1) in which tissue can be positioned between the jaws 1600, 1800and the actuated position of the closure trigger 2002 is associated witha closed or clamped position for the end effector 1500 in which tissuecan be clamped between the jaws 1600, 1800. The closure trigger 2002 cancomprise an arm 2004 that is connected either directly thereto orindirectly thereto via a mechanical linkage, such that the arm 2004rotates upon actuation of the closure trigger 2002. In one aspect, atrigger sensing assembly 2005 comprises a magnetic element 2006, such asa permanent magnet, disposed at a distal end of the arm 2004 and asensor 2008 that is configured to detect the movement of the magneticelement 2006. The sensor 2008 can comprise, for example, a Hall effectsensor configured to detect changes in a magnetic field surrounding theHall effect sensor caused by the movement of the magnetic element 2006.As the sensor 2008 can detect the movement of the magnetic element 2006and the movement of the magnetic element 2006 corresponds to theposition of the closure trigger 2002 in a known manner, the triggersensing assembly 2005 can therefore detect whether the closure trigger2002 is in the actuated position, the unactuated position, or anotherposition therebetween.

In another aspect, the trigger sensing assembly 2005 comprises a sensoror switch that is tripped when the closure drive system 510 (FIG. 1)locks the closure trigger 2002 into the fully depressed or fullyactuated position. In such an aspect, the switch can generate a signalindicating that the lock is engaged and thus that the closure trigger2002 is fully depressed.

In another aspect described in U.S. Patent Application Pub. No.2014/0296874, entitled ROBOTICALLY-CONTROLLED END EFFECTOR, which isincorporated by reference in its entirety, the trigger sensing assembly2005 comprises a force sensor positioned between the closure trigger2002 and the pivot pin 2003 about which the closure trigger 2002 pivots.In this aspect, pulling the closure trigger 2002 towards the pistol gripportion 2001 causes the closure trigger 512 to exert a force on thepivot pin 2003. The force sensor is configured to detect this force andgenerate a signal in response thereto.

The trigger sensing assembly 2005 can be in signal communication with acontroller 2102 (FIG. 25) via a wired or wireless connection such thatany signal generated by the trigger sensing assembly 2005 is relayed tothe controller 2102. The trigger sensing assembly 2005 can be configuredto continuously monitor the position of the closure trigger 2002throughout the operation of the instrument by sampling the sensedparameter(s) or transmitting a feedback signal indicative of the sensedparameter(s) with a minimal time delay. In various aspects, the triggersensing assembly 2005 can comprise an analog sensor configured togenerate a signal corresponding to the degree of force exerted on theclosure trigger 2002 and/or a particular position of the closure trigger2002. In such aspects, an analog-to-digital converter may be positionedbetween the trigger sensing assembly 2005 and the controller 2102. Invarious other aspects, the trigger sensing assembly 2005 can comprise adigital sensor configured to generate a signal indicative only ofwhether the closure trigger 2002 is actuated or unactuated.

In some aspects, the surgical instrument can include a sensor or sensorassembly that is configured to detect the thickness of tissue clamped bythe end effector. One such aspect is depicted in FIGS. 21-22, which area perspective view of an end effector 2020 comprising a tissue thicknesssensing assembly 2022 and a schematic view of a sensor 2024 of thetissue thickness sensing assembly 2022, in accordance with one or moreaspects of the present disclosure. The tissue thickness sensing assembly2022 can comprise a sensor 2024 disposed on a first jaw 2034 or RFcartridge 2042 and a magnetic element 2032, such as a permanent magnet,disposed on a second jaw 2036 of the end effector 2020. In one aspect,the sensor 2024 is disposed at or adjacent to the distal end 2038 of thefirst jaw 2034, such that it is positioned distally with respect to theelectrodes of the RF cartridge, and the magnetic element 2032 iscorrespondingly disposed at or adjacent to the distal end 2040 of thesecond jaw 2036. The sensor 2024 can comprise a magnetic field sensingelement 2026 that is configured to detect the movement of the magneticelement 2006, such as a Hall effect sensor configured to detect changesin a magnetic field surrounding the Hall effect sensor caused by themovement of the magnetic element 2032. When the operator closes the endeffector 2020, the magnetic element 2032 rotates downwardly closer tothe magnetic field sensing element 2026, thereby varying the magneticfield detected by the magnetic field sensing element 2026 as the jaw orjaws rotate into the closed (or clamped position). The strength of themagnetic field from the magnetic element 2032 sensed by the magneticfield sensing element 2026 is indicative of the distance between thefirst jaw 2034 and the second jaw 2036, which in turn is indicative ofthe thickness of the tissue clamped therebetween. For instance, a largerdistance between the first jaw 2034 and the second jaw 2036, andtherefore a weaker magnetic field detected by the magnetic field sensingelement 2026, may indicate that thick tissue is present between thefirst jaw 2034 and the second jaw 2036. Conversely, a shorter distancebetween the first jaw 2034 and the second jaw 2036, and therefore astronger magnetic field detected by the magnetic field sensing element2026, may indicate that thin tissue is present between the first jaw2034 and the second jaw 2036. The magnetic field sensing element 2026can be configured to detect and generate a signal corresponding to therelative or absolute strength of the sensed magnetic field, therebyallowing the surgical instrument to detect the relative or absolutethickness of the clamped tissue according to the resolution of themagnetic field sending elements 2026.

In another aspect, the tissue thickness sensing assembly 2022 cancomprise a displacement sensor that is disposed at the pivot jointbetween the first jaw 2034 and the second jaw 2036. In this aspect, thedisplacement sensor is configured to detect the position of the jaws2034, 2036 relative to each other, which in turn is indicative of thethickness of the tissue grasped therebetween when the end effector 2020is in the clamped position. For example, in one aspect described in U.S.Patent Application Pub. No. 2014/0296874 wherein the anvil 1810comprises pivot pins that are received within corresponding openingsdisposed on the elongate channel (FIG. 4), the tissue thickness sensingassembly 2022 can comprise a sensor positioned adjacent to, or within,the openings of the elongate channel 1602. In this aspect, as the anvil1810 is closed, the pivot pins slide through the openings and intocontact with the sensor, causing the sensor to generate a signalindicating that the anvil 1810 is closed.

In other aspects, the tissue thickness sensing assembly 2022 can furthercomprise a reed switch sensor, a displacement sensor, an optical sensor,a magneto-inductive sensor, a force sensor, a pressure sensor, apiezo-resistive film sensor, an ultrasonic sensor, an eddy currentsensor, an accelerometer, a pulse oximetry sensor, a temperature sensor,a sensor configured to detect an electrical characteristic of a tissuepath (such as capacitance or resistance), or any combination thereof. Inone such aspect, the tissue thickness sensing assembly 2022 can comprisea first electrical sensor disposed on the first jaw 2034 and acorresponding second electrical sensor disposed on the second jaw 2036,wherein the first sensor is configured to transmit an electrical currentthat is detected by the second sensor through tissue captured by the endeffector 2020. The detected current can be utilized by the tissuethickness sensing assembly 2022 to determine the thickness of theclamped tissue as tissue resistivity is a function of its thickness (andtissue type, among a variety of other factors).

The tissue thickness sensing assembly 2022 can be in signalcommunication with a controller 2102 via a wired or wireless connectionsuch that any signal generated by the tissue thickness sensing assembly2022 is relayed to the controller 2102. For example, the tissuethickness sensing assembly 2022 can comprise a transmitter 2028configured to transmit the signals generated by the magnetic fieldsensing element 2026 via a wired or wireless connection to a receiver,which in turn is communicably coupled to the controller 2102. The tissuethickness sensing assembly 2022 can be configured to continuouslymonitor the thickness of the clamped tissue throughout the operation ofthe instrument by sampling the sensed parameter(s) or transmitting afeedback signal indicative of the sensed parameter(s) with a minimaltime delay. In various aspects, the tissue thickness sensing assembly2022 can comprise an analog sensor configured to generate a signalcorresponding to relative or absolute thickness of the clamped tissueand/or a particular position of either of the first jaw 2034 or thesecond jaw 2036. In such aspects, an analog-to-digital converter may bepositioned between the tissue thickness sensing assembly 2022 and thecontroller 2102. In various other aspects, the tissue thickness sensingassembly 2022 can comprise a digital sensor configured to generate asignal indicative only of whether the jaws 2034, 2036 are opened orclosed.

In some aspects, the tissue thickness sensing assembly 2022 can furthercomprise a power source 2030 operably connected to the magnetic fieldsensing element 2026. The power source 2030 can be separate from anyother power source associated with the surgical instrument.Alternatively, the issue thickness sensing assembly 2022 can beinterconnected with one or more power sources associated with thesurgical instrument.

In some aspects, the surgical instrument can include a sensor or sensorassembly configured to detect the position of the longitudinally movabledrive member 540 (FIG. 3), knife bar 1320 (FIG. 4), knife member 1330(FIG. 4), cutting blade 1334 (FIG. 4), and/or other components of thefiring drive system 530 (FIG. 3). In various aspects, the positionsensing assembly 2050 can be configured to track the linear displacementof the component of the firing drive system 530 utilizing sensorsconfigured to track the rotation of a gear arrangement 2054 engaged withthe firing drive system 530. For example, FIG. 23 is an explodedperspective view of a position sensing assembly 2050 configured todetect and track the linear position of the longitudinally movable drivemember 540. In the aspect illustrated in FIG. 23, the surgicalinstrument comprises a drive gear 2058 that is operably driven through adrive shaft 2056 by the electric motor 505 (FIG. 1). The drive gear 2058meshingly engages the rack of drive teeth 542 (FIG. 3) of thelongitudinally movable drive member 540, thereby allowing the motor 505to drive the linear displacement of the longitudinally movable drivemember 540. Rotation of the drive gear 2058 in a first direction causesthe longitudinally movable drive member 540 to advance in a distaldirection and rotation of the drive gear 2058 in a second directioncauses the longitudinally movable drive member 540 to retract in aproximal direction P. In various aspects, the gear arrangement 2054 ofthe position sensing assembly 2050 can be positioned at or adjacent tothe drive gear 2058 engaged with the longitudinally movable drive member540, as illustrated in FIG. 23. In other aspects, the gear arrangement2054 of the position sensing assembly 2050 can be positioned downstreamof the drive gear 2058 in the firing drive system 530 and/or engagedwith other components of the firing drive system 530.

In the illustrated aspect, the gear arrangement 2054 of the positionsensing assembly 2050 comprises a first gear 2052 that rotates about theshaft 2056 accordingly to the rotation of the drive gear 2058. Thus,rotation of the first gear 2052 about the shaft 2056 corresponds to thelongitudinal translation of the longitudinally movable drive member 540as driven by the drive gear 2058. The position sensing assembly 2050further comprises a magnet 2064 that rotates in a manner correspondingto the rotation of the first gear 2052. In one aspect, the magnet 2064is disposed on the first gear 2052. In this aspect, one revolution ofthe first gear 2052, and thus the magnet 2064, corresponds to onerevolution of the drive gear 2058. In another aspect, the geararrangement 2054 is configured to serve as a gear reducer assemblyproviding an alternative ratio between the number of revolutions of thedrive gear 2058 and the magnet 2064. In one such aspect illustrated inFIG. 23, the gear arrangement 2054 comprises a second gear 2060, whichis meshingly engaged with the first gear 2052. In this aspect, themagnet 2064 is disposed on the second gear 2060. The gear ratioconnection between the first gear 2052 and the second gear 2060 can beconfigured such that a single revolution of the magnet 2064 correspondsto a set linear displacement of the longitudinally movable drive member540. For example, the gear ratio connection between the first gear 2052and the second gear 2060 can be configured such that a single revolutionof the magnet 2064 can correspond to a full stroke of the longitudinallymovable drive member 540. Thus, one full stroke of the longitudinallymovable drive member 540 in either the distal or proximal directionscorresponds to a single rotation of the second gear 2060. Since themagnet 2064 is coupled to the second gear 260, the magnet 2064 thusmakes one full rotation with each full stroke of the longitudinallymovable drive member 540.

The position sensing assembly 2050 further comprises a position sensor2070 operably connected to a circuit 2072. The position sensor 2070comprises one or more magnetic sensing elements, such as Hall effectelements, and is positioned in proximity to the magnet 2064. As themagnet 2064 rotates, the magnetic sensing elements of the positionsensor 2070 determine the absolute angular position of the magnet 2064over a revolution. In aspects of the surgical instrument wherein onerevolution of the magnet 2064 corresponds to one full stroke of thelongitudinally movable drive member 540, the particular angular positionof the magnet 2064 thus corresponds to a particular linear position ofthe longitudinally movable drive member 540. In one aspect, the positionsensing assembly 2050 is configured to provide a unique position signalcorresponding to the location of the longitudinally movable drive member540 according to the precise angular position of the magnet 2064 asdetected by the position sensor 2070.

The position sensor 2070 can comprise any number of magnetic sensingelements, such as magnetic sensors classified according to whether theymeasure the total magnetic field or the vector components of themagnetic field. A series of n switches, where n is an integer greaterthan one, may be employed alone or in combination with gear reduction toprovide a unique position signal for more than one revolution of themagnet 2064. The state of the switches can be fed back to a controller2080 that applies logic to determine a unique position signalcorresponding to the linear displacement of the longitudinally movabledrive member 540.

In one aspect, the position sensor 2070 is supported by a positionsensor holder 2066 defining an aperture 2068 configured to contain theposition sensor 270 in precise alignment with the magnet 2064 rotatingbelow. The magnet 2064 can be coupled to a structural element 2062, suchas a bracket, that supports to gear arrangement 2054 and to the circuit2072.

FIG. 24 is a diagram of a circuit 2072 and a position sensor 2070 of aposition sensing assembly 2050, in accordance with one or more aspectsof the present disclosure. The position sensor 2070 may be implementedas an AS5055EQFT single-chip magnetic rotary position sensor availablefrom Austria Microsystems, AG. The position sensor 2070 is interfacedwith a controller 2080, such as a microcontroller, to provide a systemthat is able to detect the absolute position of the longitudinallymovable drive member 540 and/or other components of the firing drivesystem 530. In one aspect, the position sensor 2070 is a low-voltage andlow-power component and includes four Hall effect elements 2078A, 2078B,2078C, 2078D in an area 2076 of the position sensor 2070 that is locatedabove the magnet 2064. A high-resolution ADC 2082 and a smart powermanagement controller 2084 are also provided on the chip. A CORDIC(Coordinate Rotation Digital Computer) processor 2086, also known as thedigit-by-digit method and Volder's algorithm, is provided to implement asimple and efficient algorithm to calculate hyperbolic and trigonometricfunctions that require only addition, subtraction, bitshift, and tablelookup operations. The angle position, alarm bits, and magnetic fieldinformation are transmitted over a standard serial communicationinterface, such as an SPI interface 2088, to the controller 2080. Theposition sensor 2070 provides 12 or 14 bits of resolution. The positionsensor 2070 may be an AS5055 chip provided in a small QFN 16-pin4×4×0.85 mm package. In the AS5055 position sensor 2070, the Hall effectelements 2078A, 2078B, 2078C, 2078D are capable producing a voltagesignal that is indicative of the absolute position of the magnet 2064 interms of the angle over a single revolution of the magnet 264. Thisvalue of the angle, which is unique position signal, is calculated bythe CORDIC processor 286 is stored onboard the AS5055 position sensor2070 in a register or memory. The value of the angle that is indicativeof the position of the magnet 2064 over one revolution is provided tothe controller 2080 in a variety of techniques, e.g., upon power up orupon request by the controller 2080.

Although the position sensor 2070 is depicted in FIG. 24 as includingfour Hall effect elements, in other aspects of the surgical instrument,the number of Hall effect elements included in the position sensor 2070can vary. Generally, the number of Hall effect elements will correspondto the degree of resolution desired for the position sensor 2070 as alarger number of Hall effect elements would allow the position sensor2070 to detect finer movements of the longitudinally movable drivemember 540. In various aspects, the distance between the Hall effectelements can be uniform, i.e., the Hall effect elements can be evenlypositioned, so that each Hall effect element corresponds to a setdisplacement distance of the longitudinally movable drive member 540.Additional aspects of the position sensing assembly 2050, the circuit2072, and the position sensor 2070 are described in U.S. PatentApplication Ser. No. 15/130,590, entitled SYSTEMS AND METHODS FORCONTROLLING A SURGICAL STAPLING AND CUTTING INSTRUMENT, which isincorporated by reference in its entirety.

In other aspects, the knife bar 1320, knife member 1330, cutting blade1334, and/or other components of the firing drive system 530 couldalternatively be configured to include a rack of drive teeth thatmeshingly engage the gear arrangement 2054 of the position sensingassembly 2050. In such aspects of the surgical instrument, the positionsensing assembly 2050 is configured to track the linear displacement ofthe particular component of the firing drive system 530, rather thanbeing connected to the drive gear 2058 and/or shaft 2056 driving thedisplacement of the longitudinally movable drive member 540.Accordingly, it should be appreciated that the principles discussed withrespect to the aspect wherein the displacement of the longitudinallymovable drive member 540 is tracked are equally applicable to aspects ofa position sensing assembly 2050 configured to detect the lineardisplacement of the knife bar 1320, knife member 1330, cutting blade1334, and/or other components of the firing drive system 530.

In other aspects, the position sensing assembly 2050 comprises contactor non-contact linear displacement sensors configured to track thelinear displacement of the firing drive system 530. The lineardisplacement sensors can comprise linear variable differentialtransformers (LVDT), differential variable reluctance transducers(DVRT), a slide potentiometer, a magnetic sensing system comprising amovable magnet and a series of linearly arranged Hall effect sensors, amagnetic sensing system comprising a fixed magnet and a series ofmovable linearly arranged Hall effect sensors, an optical sensing systemcomprising a movable light source and a series of linearly arrangedphoto diodes or photo detectors, or an optical sensing system comprisinga fixed light source and a series of movable linearly arranged photodiodes or photo detectors, or any combination thereof.

FIG. 25 is a block diagram of one example of a surgical instrument 2100programmed to display various statuses of the surgical instrument 2100,in accordance with one or more aspects of the present disclosure. Thesurgical instrument 2100 comprises a controller 2102 that is operablyconnected to one or more sensors 2104, 2106 and a display 2108, whichmay be disposed on the exterior casing of the surgical instrument 2100.The controller 2102 embodies or executes a logic that controls theoperation of the surgical instrument 2100 according to a variety ofinputs, such as signals received from the one or more sensors 2104, 2106with which the controller 2102 is in signal communication. In variousaspects, the controller 2102 comprises a processor, such as a CPU,operably connected to a memory 2110 storing program instructions that,when executed by the processor, cause the controller 2102 and/orsurgical instrument 2100 to execute a process dictated by the programinstructions. In other aspects, the controller 2102 comprises a controlcircuit that is configured to execute a process according to digital oranalog signal input. The control circuit can comprise an ASIC, a FPGA,or any other circuit that is manufacturable or programmable to execute alogic.

The controller 2102 is configured to display various statuses associatedwith the use of the surgical instrument 2100 on the display 2108according to input received from a variety of sensors. One such sensorincludes the position sensor 2104, which can include the positionsensing assembly 2050 (FIG. 23), as described above. Other sensors 2106from which the controller 2102 receives input can include the triggersensing assembly 2005 (FIGS. 19-20) and the tissue thickness sensingassembly 2022 (FIGS. 21-22), as described above.

The surgical instrument 2100 further includes a motor 2116, such as anelectric motor, that drives a rotatable shaft 224, which operablyinterfaces with a gear assembly 2122 that is mounted in meshingengagement with a set, or rack, of drive teeth, such as in a rack andpinion arrangement, on a displacement member 2118. In the positionsensing assembly 2050, the displacement member 2118 can include, forexample, the longitudinally movable drive member 540 of the firing drivesystem 530. A sensor element or magnet 2120 can be operably coupled to agear assembly 2122 such that a single revolution of the magnet 2120corresponds to some linear longitudinal translation of the displacementmember 2118. The position sensor 2104 can then further include aplurality of magnetic sensing elements configured to detect the angularposition of the magnet 2120, which corresponds to the linear position ofthe displacement member 2118 and thus allows the position sensor 2104 todetect the absolute or relative position of the displacement member2118. The position sensor 2104 can further be configured to relay afeedback signal to the controller 2102 that is indicative of theposition of the displacement member 2118. A driver 2114 is operablyconnected to the motor 2116 and configured to provide a drive signalthereto that sets the velocity at which the motor 2116 is driven, thecurrent drawn by the motor 2116, the voltage at which the motor 2116 isset, or a variety of other motor 2116 characteristics. A power source2112 supplies power to any or all of the driver 2114, motor 2116,controller 2102, display 2108, sensors 2104, 2106, or other componentsof the surgical instrument 2100.

In some aspects, the surgical instrument 2100 can include a sensingassembly that is configured to detect the progress or advancement of theclosure mechanism. In various aspects, the closure mechanism sensingassembly can comprise the trigger sensing assembly 2005 described above.As the closure trigger 512 is utilized to actuate the closure drivesystem 510, which in turn causes the closure shuttle 1914 (FIG. 5) toadvance, the actuation or position of the closure trigger 512 can thusbe detected as a proxy for the progress or advancement of the closuremechanism.

In other aspects, the closure mechanism sensing assembly can be similarto the position sensing assembly 2050 described above with respect tothe firing drive system 530 and illustrated in FIGS. 23-24. The closuremechanism sensing assembly of the surgical instrument 2100 can includethe position sensor 2104, which can be provided in addition to or inlieu of the position sensor described with respect to the positionsensing assembly 2050. In these aspects, the displacement member 2118can include one or more components of the closure mechanism, such as theclosure shuttle 1914, proximal closure tube 1910, and/or distal closuretube 1930, comprise rack of drive teeth that are meshingly engaged witha corresponding gear assembly 2122 supporting a magnet 2120 thereon. Asthe displacement member 2118 of the closure mechanism advances distallyor proximally, the magnet 2120 is caused to rotate in a first directionor a second direction. The position sensor 2104 further includes aplurality of magnetic sensing elements, such as Hall effect elements,that are positioned in proximity to the magnet 2120. As the magnet 2120rotates, the magnetic sensing elements of the position sensor 2104determine the absolute angular position of the magnet 2120 over arevolution. As the angular position of the magnet 2120 corresponds tothe position of the displacement member 2118 of the closure mechanismwith which the gear assembly 2122 is engaged, the closure tube sensingassembly can thus detect the absolute position of the component of theclosure mechanism. Additional details regarding these aspects of theclosure mechanism sensing assembly are described above with respect tothe position sensing assembly 2050.

The velocity at which the knife bar 1320 is being translated by thefiring drive system 530 and/or the end effector 1500 is being closed bythe closure mechanism can be determined in various aspects utilizing aposition sensor 2104 to track the position of a displacement member 2118in combination with a timer or timing circuit. As the displacementmember 2118 is being translated, the position sensor 2104 can determineits position d₁, d₂, . . . d_(n) at a series of discrete time intervalsor time stamps t₁, t₂, . . . t_(n) provided by the timer. The timer caninclude a continuously running timer, i.e., a clock, or a timer that isinitiated upon activation of either of the firing or closure mechanisms.In one aspect, for each discrete position measurement taken by theposition sensor 2104, the controller 2102 accesses the timer to retrievea time stamp according to the receipt time of the position measurement.The controller 2102 can then calculate the velocity of the displacementmember 2118 over a set time period according to the change in itsdisplacement position over time. As the velocity of the displacementmember 2118 corresponds in a known manner to either the velocity atwhich the knife bar 1320 is translated or the velocity at which the endeffector 1500 is closed, the controller 2102 can thus determine thefiring or closure velocity of the surgical instrument 2100.

The other sensors 2106 can additionally include a cartridge sensor. Inone aspect, the cartridge sensor includes the channel circuit 1670 (FIG.10), which can be configured to detect the presence and/or status of anRF cartridge 1700 via the exposed contacts 1676 positioned to makeelectrical contact with the corresponding exposed contacts 1756 of theRF cartridge 1700. In another aspect, the cartridge sensor includes asensor, such as the cartridge present sensor and/or cartridge conditionsensor disclosed in U.S. Patent Application Pub. No. 2014/0296874, thatis positioned with the elongated channel 1602 comprising electricalcontacts that output a logic zero when the circuit is open and a logicone when the circuit is closed, i.e., the RF cartridge 1700 ispositioned correctly within the elongated channel 1602.

The other sensors 2106 can additionally include a temperature sensorthat is configured to detect the temperature of the tissue being sealedby the RF energy. In one aspect, the temperature sensor includes atemperature sensing circuit disclosed as described in U.S. Pat. No.8,888,776, entitled ELECTROSURGICAL INSTRUMENT EMPLOYING AN ELECTRODE,which is incorporated by reference in its entirety. In this aspect, thetemperature sensing circuit can be configured to apply a voltagepotential that is a function of the temperature sensed by thetemperature sensing circuit. The temperature sensing circuit can beconfigured to apply a first voltage potential to the gate terminal whenit detects a first temperature, a second voltage potential when itdetects a second temperature, and a third voltage potential when itdetects a third temperature, and so forth. In various aspects, thetemperature sensing circuit can decrease the voltage potential appliedto the gate terminal as the temperature of the electrode increases. Forexample, the temperature sensing circuit can be configured to apply afirst voltage potential to the gate terminal when a first temperature isdetected by the temperature sensing circuit and, in addition, a secondvoltage potential, which is lower than the first voltage potential, whenthe temperature sensing circuit detects a second temperature which ishigher than the first temperature. Correspondingly, the temperaturesensing circuit can increase the voltage potential applied to the gateterminal as the temperature of the electrode decreases. The change inthe voltage potential generated by the temperature sensing circuit canbe detected by, for example, a circuit in order to generate a feedbacksignal indicative of the temperature experienced or sensed by thecircuit that is then transmitted to the controller 2102. The temperaturesensing circuit can be included with the first jaw 1600 (FIG. 3), thesecond jaw 1800 (FIG. 3), and/or the cartridge 1700 (FIG. 2). In aspectswherein the cartridge 1700 includes the temperature sensing circuit, thefeedback signal generated by the temperature sensing circuit can betransmitted to the channel circuit 1670 through the electricalconnection between the corresponding exposed contacts 1676, 1756. Thechannel circuit 1670 can then transmit the feedback signal to thecontroller 2102.

The other sensors 2106 can additionally include tissue sensors that areconfigured to measure one or more characteristics of the tissueundergoing to clamping, sealing, stapling, and/or cutting operations ofthe surgical instrument 2100. In one aspect, the other sensors 2106comprise a tissue impedance sensor that is configured to measure theimpedance of the clamped tissue as RF energy is applied. The tissueimpedance sensor comprises, for example, electrodes and an impedancemonitoring circuit that are configured to measure the current betweenthe electrodes and/or the impedance of the tissue between theelectrodes, as described in U.S. Pat. No. 5,817,093, entitled IMPEDANCEFEEDBACK MONITOR WITH QUERY ELECTRODE FOR ELECTROSURGICAL INSTRUMENT,which is incorporated by reference in its entirety. The electrodes ofthe tissue impedance sensor can be the same electrodes 1736R, 1736L,1738R, 1738R for delivery of the therapeutic RF energy or differentelectrodes. In aspects wherein the tissue impedance sensor electrodesare different than the therapeutic electrodes, the frequency of RFenergy delivered through the tissue impedance sensor electrodes can bedifferent from the frequency of energy delivered through the therapeuticelectrodes to reduce electrical interference. The tissue impedancesensor electrodes comprise at least two electrically opposite electrodesthat are arranged on the end effector 1500 such that they contact thetissue clamped thereby. The tissue impedance sensor electrodes can belocated either on the same surface or opposing surfaces of the endeffector 1500 between a portion of the engaged tissue. As the voltagesupplied to the tissue impedance sensor electrodes by, for example, theRF generator 400 (FIG. 1) is known and the current between theelectrodes is detectable by the impedance monitoring circuit, theimpedance of the tissue is thus calculable. In one aspect, the impedancemonitoring circuit can calculate the impedance of the clamped tissueitself and then transmit a feedback signal indicative of the impedanceto the controller 2102. In another aspect, the impedance monitoringcircuit can transmit a feedback signal indicative of the detectedcurrent between the electrodes to the controller 2102, which thencalculates the impedance of the tissue.

In totality, the various sensors or sensor assemblies disclosed hereincan be utilized by the surgical instrument 2100 to monitor the positionof the closure trigger 512, the advancement of the closure drive system510 and/or components of the closure mechanism, the thickness of theclamped tissue, the position of the knife bar 1320 and/or othercomponents of the firing drive system 530, the presence of the RFcartridge 1700, the status of the RF cartridge 1700, the closure speedof the end effector 1500, and various other operational statuses of thesurgical instrument 2100. These states, parameters, positions, or otherinformation associated with the operation of the surgical instrument2100 can be tracked by the controller 2102 through feedback signalstransmitted from the various sensing assemblies. The controller 2102 canthen cause the display 2108 to display one or more of the monitoredvariables associated with the operation of the surgical instrument 2100in a graphical format for viewing by the operators of the surgicalinstrument 2100.

FIGS. 26-39 are displays depicting various statuses, parameters, orother information associated with the operation of the surgicalinstrument, in accordance with one or more aspects of the presentdisclosure. In various aspects depicted in FIGS. 26-29, the display 2200of the surgical instrument can be configured to graphically representthe status of the RF energy being supplied to the tissue engaged by theend effector 1500 (FIG. 1). The status of the supplied RF energy can berepresented in the format of a graph 2202, a numerical value 2204, adial 2206, or a bar graph 2208. The RF energy delivered to the tissuecorresponds to the tissue impedance 2210 measured, for example, by atissue impedance sensor, as described above. Furthermore, the tissueimpedance 2210 varies as a function of time 2212 because the propertiesof the engaged tissue change due to the application of mechanical forcefrom the jaws of the end effector 1500 and RF energy. One such change inthe properties of the engaged tissue is the egress of water from thetissue. Another such change in the properties of the engaged tissue isthe change in conductance of the tissue fibers as RF energy is applied.Therefore in some aspects, the display 2200 can be configured to depictthe change in tissue impedance 2210 over time 2212 as, for example, acurve 2216 in a graph 2202 or a series of bars 2224 indicatingmeasurements of the tissue impedance 2210 at discrete time intervals ina bar graph 2208. The display 2200 can additionally be configured todepict an expected curve 2217 of the impedance 2210 over time 2212 thatis calculated by the controller 2102 according to an algorithm executedthereby. In other aspects, the display 2200 can represent the tissueimpedance 2210 as a numeral 2218. The numeral 2218 can represent theabsolute value of the measured impedance in, for example, ohms.Alternatively, the numeral 2218 can represent the relative value orratio of the measured impedance between a maximum and minimum impedancevalue. Furthermore, the size that the numeral 2218 is depicted on thedisplay 2200 can correspond to the relative size of the value. The dial2206 format of the display 2200 can likewise depict the measured tissueimpedance relative to a maximum impedance 2222 and a minimum impedance2220.

The display 2200 can also be configured to depict one or more alerts2214 or statuses 2226 according to the operation of the surgicalinstrument 2100. The alerts 2214 can include warnings that the tissueimpedance has exceeded a maximum tissue impedance, that the electrodeshave lost energy, that the measured tissue impedance is deviating froman expected tissue impedance as calculated by the controller 2102 orstored on the memory 2110, and that the application time of the RFenergy has exceeded a maximum or expected time. The statuses 2226 caninclude the current or subsequent stage or step of the process of usingthe surgical instrument 2100.

In addition to displaying the RF energy being supplied to the tissue,the display 2200 can also be configured to depict a variety of otherparameters, statuses, or other information as determined by the sensingassemblies in communication with the controller 2102. In one aspect, thedisplay 2200 can be configured to depict a temperature status 2228 ofthe tissue to which RF energy is being applied. The temperature can bedetermined by, for example, a temperature sensing circuit, as describedabove. In various aspects, the temperature status 2228 can be depictedas an absolute value of the measured temperature or a relative value ofthe measured temperature between a minimum and maximum temperature. Inone aspect, the temperature status 2228 can be depicted as a curve 2239of the absolute or relative temperature 2236 as a function of time 2238.The display 2200 can additionally be configured to depict an expectedcurve 2240 of the temperature 2236 over time 2238 that is calculated bythe controller 2102 according to an algorithm executed thereby.

In another aspect, the display 2200 can be configured to depict thewater content status 2230 of the tissue. The water content of the tissuecan be determined, for example, as a function of the change in impedanceof the tissue during the clamping and RF sealing operations executed bythe surgical instrument 2100. As the change in mechanical properties ofa particular tissue type over time are experimentally known and thechange in tissue impedance as a result of the change in tissuemechanical properties is likewise experimentally known, the controller2102 can isolate these effects from the measured change in tissueimpedance over time, calculate the change in tissue water content, andthen cause the display 2200 to depict the calculated water contentstatus 2230. As described above with respect to other tissue or surgicalinstrument parameters, the display 2200 can depict the tissue watercontent status 2230 in the format of a graph, a numeral, a dial, or anyother such graphical representation. In one aspect, the display 2200 candepict the change in tissue water content 2242 over time 2244 as a curve2246. The display 2200 can additionally be configured to depict anexpected curve 2248 of the water content 2242 over time 2244 that iscalculated by the controller 2102 according to an algorithm executedthereby.

In other aspects, the display 2200 can be configured to depict the sealcompletion status 2232 or completion status 2234 according to theoperation of the surgical instrument 2100. The seal completion status2232 can correspond, for example, to the RF energy status depicted inFIGS. 26-29 and indicate the currently measured delivery of RF energyrelative to an expected value. For example, in FIG. 32 the sealcompletion status 2232 is depicted graphically as a measured curve 2254of the tissue impedance 2250 over time 2252 as compared to an expectedcurve 2256 of the tissue impedance 2250 over time 2252. The ratiobetween the measured curve 2254 and the expected curve 2256 graphicallydepicts the relative progress of the application of RF energy relativeto an expected progress, which can be determined experimentally andstored on the memory 2110 to be accessed by the controller 2102. In oneaspect, the completion status 2234 can represent the seal completionstatus in an alternative graphical format. In another aspect, thecompletion status 2234 can represent the percentage of number of stepsexecuted or completed by the surgical instrument 2100 or the percentagecompletion of any individual step, such as the advancement of theclosure mechanism or the current longitudinal displacement of the knifebar 1320 (FIG. 4) relative to the total longitudinal displacementthereof in the step of firing the knife bar 1320. The current progresscan be tracked by the controller 2102 in combination with the varioussensing assemblies of the surgical instrument 2100. The completionstatus 2234 can be displayed in the format of a dial depicting apercentage 2258 between a minimum percentage 2260 and a maximumpercentage 2262.

In various aspects depicted in FIGS. 34-37, the display 2200 can beconfigured to display the thickness of the tissue engaged by the endeffector 1500, the advancement of a displacement member, such as theknife bar 1320, and various statuses associated with the tissuethickness and/or the displacement member. The thickness of the tissueengaged by the end effector 1500 can be detected, e.g., by a tissuethickness sensing assembly 2022 in communication with the controller2102, as described above. In various aspects, the controller 2102 cancause the display 2200 to depict the tissue thickness according to thefeedback signal generated by the tissue thickness sensing assembly 2202as either an absolute or a relative value in a variety of differentgraphical formats, such as a series of discrete zones 2264 ranging fromthin to thick, as a graph 2266, or as a dial 2268, among others.

The display 2200 can additionally comprise alerts to provide graphicalwarnings to users that the tissue is too thick or too thin for aparticular operation. For example, an alert can comprise an icon 2274,such as an “X” as depicted in FIG. 35, that is overlaid on the display2200 to indicate to the operator that the surgical instrument 2100 iscurrently or will be operating outside of desired conditions. In otheraspects, the icon 2274 may or may not be overlaid on the variousgraphical formats 2264, 2266, 2268 indicating tissue thickness. Variousother graphical warnings can be utilized, including icons of differentdesigns, changes in color, or textual warnings. As another example, analert can comprise a graphical depiction that a curve 2276 of the tissuethickness, displacement member velocity, or other parameter measured byor calculated from the various sensing assemblies is deviating from anexpected curve 2278. In such aspects, various other additional alertscan accompany the depicted alert, such as textual alerts, icons, changesin color, and the like.

In one aspect, the display 2200 can additionally be configured to depictthe position of the knife bar 1320. The position of the knife bar 1320can be detected by, for example, a position sensing assembly 2050 incommunication with the controller 2102, as described above. In variousaspects, the controller 2102 can cause the display 2200 to depict theknife bar 1320 displacement according to the feedback signal generatedby the position sensing assembly 2050 as, for example, a linear measuredposition 2270 of the knife bar 1320 relative to a maximum position 2272thereof. The maximum position 2272 can include a maximum incision lengthdesired for a particular surgical operation or an absolute maximumlength that the knife bar 1320 can translate.

In another aspect, the display 2200 can additionally be configured todepict the advancement or status of the closure mechanism. Theadvancement of the closure mechanism can be detected, e.g., by a closuretrigger sensing assembly 2005 in communication with the controller 2102,as discussed above, or a position sensing assembly 2050 configured todetect a position of a displacement member 2118 of the closuremechanism, as described above with respect to FIG. 25. In variousaspects, the controller 2102 can cause the display 2200 to depict theclosure mechanism advancement according to the feedback signal generatedby the trigger sensing assembly 2005 or the position sensing assembly2050 as, for example, a detected position of the closure shuttle 1914relative to a maximum position thereof.

In some aspects, the controller 2102 can be configured to populate thedisplay 2200 with a variety of icons when certain events or statusesoccur. For example, a first icon 2280 can indicate that RF energy iscurrently or has been successfully applied to the tissue. A second icon2282 can indicate that the knife bar 1320 is currently or has beensuccessfully fired. A third icon 2284 can indicate that an error hasoccurred at some point during the operation of the instrument. A fourthicon 2286 can indicate that all of the steps of the operation of theinstrument have been successfully completed. A fifth icon 2288 canindicate that an error has occurred with a specific component of theinstrument, such as the knife bar 1320. The display 2200 canadditionally be configured to display any other such type of iconindicating that a step or process is complete or that an event hasoccurred, such as an error. The various icons can be configured toilluminate, become visible, or change color when the status is active orthe event has occurred.

In some aspects, the display 2200 can be configured to indicate whethera correct or incorrect cartridge type has been loaded into the endeffector 1500, i.e., inserted into the elongate channel 1602 (FIG. 10).The channel circuit 1670 can be configured to read or detect the type ofcartridge that is received by the end effector 1500 via a sensor orelectrical communication between the channel circuit 1670 and thecartridge. In one aspect, the cartridges comprise a memory storing anidentifier or value indicative of the cartridge type that is transmittedto the channel circuit 1670 upon the cartridge being inserted into theelongate channel 1602 of the end effector 1500. The channel circuit1670, which is communicably coupled to the controller 2102, isconfigured to then transmit the cartridge type identifier or value tothe controller 2102. The logic executed by the controller 2102 can thencompare the cartridge type to the expected cartridge type. If thecartridge type and the expected cartridge type do not match, then thecontroller 2102 can cause the display 2200 to depict a first icon 2290.If the cartridge type and the expected cartridge type do match, then thecontroller 2102 can cause the display 2200 to depict a second icon 2292.In the aspect depicted in FIGS. 38-39, the first icon 2290 correspondsto a staple cartridge being inserted when an RF cartridge is expectedand the second icon 2292 corresponds to an RF cartridge being insertedwhen an RF cartridge is expected.

The various aspects of the display 2200 depicted in FIGS. 26-39 canrepresent individual representations of a screen displayed to anoperator or portions of a screen displayed to an operator. In variousaspects, operators can switch between the various screens via user inputor the controller 2102 can automatically adjust the display 2200according to the operation of the surgical instrument 2100. In variousaspects, the display 2200 can include a graphical user interface thatcan be manipulated via, for example, a capacitive touchscreen.

The display 2200 as described herein can include one or more screensdisposed on or connected with the surgical instrument for graphicallydisplaying information captured by the various sensing assemblies. Inone aspect, the display 2200 comprises a single screen positioned on theexterior casing of the surgical instrument, as depicted in FIG. 1. Inaspects utilizing multiple screens, the screens can be positionedadjacently to each other or separately from each other. The display 2200can be positioned directly on the surgical instrument, can be removablyconnectable to the surgical instrument such that the display 2200 isbrought into signal communication with the controller when connected tothe surgical instrument, or can be otherwise associated with thesurgical instrument.

The functions or processes of monitoring various statuses of thesurgical instrument via various sensing assemblies described herein maybe executed by any of the processing circuits, either individually or incombination, described herein, such as the onboard circuit board 1152described in connection with FIGS. 5 and 15, the channel circuit 1670described in connection with FIG. 10, the flexible circuit assemblies1730L, 1730R described in connection with FIGS. 10-13, the controller2080 described in connection with FIG. 24, and the controller 2102described in connection with FIG. 25.

Various aspects of the subject matter described herein are set out inthe following examples:

EXAMPLE 1

A surgical instrument comprising: a circuit configured to deliver RFenergy to a cartridge disposed in an end effector configured to receivethe cartridge; a closure mechanism configured to transition the endeffector between an open position and a closed position; a display; anda control circuit operably coupled to the display, the control circuitconfigured to: determine an amount of RF energy delivered to a tissuethrough the cartridge; display the amount of RF energy on the display;determine a position of the closure mechanism; and display the positionof the closure mechanism on the display.

EXAMPLE 2

The surgical instrument of Example 1, wherein the control circuit isconfigured to receive a signal from an impedance sensor configured tomeasure an impedance of the tissue disposed between a first electrodeand a second electrode, wherein the control circuit is configured todetermine the amount of RF energy delivered to the tissue according tothe impedance of the tissue.

EXAMPLE 3

The surgical instrument of one or more of Example 1 through Example 2,wherein the control circuit is configured to receive a signal from aposition sensor configured to detect a position of a displacement memberof the closure mechanism, wherein the control circuit is configured todetermine the position of the closure mechanism according to theposition of the displacement member.

EXAMPLE 4

The surgical instrument of one or more of Example 1 through Example 3,further comprising: a closure trigger configured to drive the closuremechanism between a first position and a second position; and a closuretrigger sensor configured to detect a position of the closure trigger;wherein the control circuit is configured to determine the position ofthe closure mechanism according to the position of the closure trigger.

EXAMPLE 5

The surgical instrument of one or more of Example 1 through Example 4,wherein the control circuit is configured to receive a signal from asensor configured to detect a position of the end effector between theopen position and the closed position, wherein the control circuit isconfigured to determine the position of the closure mechanism accordingto the position of the end effector.

EXAMPLE 6

The surgical instrument of one or more of Example 1 through Example 5,wherein the control circuit is configured to receive a signal from acartridge sensor configured to detect a cartridge type of the cartridgereceived by the end effector, wherein the control circuit is configuredto display whether the cartridge type matches an expected cartridge typeon the display.

EXAMPLE 7

A surgical instrument comprising: a circuit configured to deliver RFenergy to a cartridge disposed in an end effector; a closure mechanismconfigured to transition the end effector between an open position and aclosed position; a display; and a processor operably coupled to thedisplay; a memory operably coupled to the processor, the memory storingprogram instructions that, when executed by the processor, cause theprocessor to: determine a status of RF energy delivered to a tissuethrough the cartridge; display the status of RF energy; determine astatus of the closure mechanism; and display the status of the closuremechanism.

EXAMPLE 8

The surgical instrument of Example 7, wherein the memory stores programinstructions that when executed by the processor, cause the processor toreceive a signal from an impedance sensor configured to measure animpedance of the tissue between a first electrode and a secondelectrode, wherein the processor is configured to determine the statusof RF energy applied to the tissue according to the impedance of thetissue.

EXAMPLE 9

The surgical instrument of Example 7, wherein the memory stores programinstructions that when executed by the processor, cause the processor toreceive a signal from a position sensor configured to detect a positionof a displacement member of the closure mechanism, wherein the processoris configured to determine the status of the closure mechanism accordingto the position of the displacement member.

EXAMPLE 10

The surgical instrument of one or more of Example 7 through Example 9,further comprising: a closure trigger configured to drive the closuremechanism between a first position and a second position; and a closuretrigger sensor configured to detect a position of the closure trigger;wherein the surgical instrument determines the status of the closuremechanism according to the position of the closure trigger.

EXAMPLE 11

The surgical instrument of one or more of Example 7 through Example 10,wherein the memory stores program instructions that when executed by theprocessor, cause the processor to receive a signal from a sensorconfigured to detect a position of the end effector between the openposition and the closed position, wherein the processor is configured todetermine the status of the closure mechanism according to the positionof the end effector.

EXAMPLE 12

The surgical instrument of one or more of Example 7 through Example 11,wherein the memory further stores program instructions that whenexecuted by the processor, cause the processor to receive a signal froma cartridge sensor configured to detect a cartridge type of thecartridge received by the end effector, wherein the processor isconfigured to display whether the cartridge type matches an expectedcartridge type on the display.

EXAMPLE 13

A method of controlling a display in a surgical instrument, the surgicalinstrument comprising a circuit configured to deliver RF energy to acartridge disposed within an end effector configured to receive thecartridge, a closure mechanism configured to transition the end effectorbetween an open position and a closed position, a display, and a controlcircuit coupled to the display, the method comprising: determining, bythe control circuit, an amount of RF energy applied to a tissue throughthe cartridge; displaying, by the control circuit, the amount of RFenergy on the display; determining, by the control circuit, a positionof the closure mechanism; and displaying, by the control circuit, theposition of the closure mechanism on the display.

EXAMPLE 14

The method of Example 13, further comprising: measuring, by an impedancesensor, an impedance of the tissue between a first electrode and asecond electrode: wherein the control circuit determines the amount ofRF energy applied to the tissue according to the impedance of thetissue.

EXAMPLE 15

The method of one or more of Example 13 through Example 14, furthercomprising: detecting, by a position sensor, a position of adisplacement member of the closure mechanism; wherein the controlcircuit determines the position of the closure mechanism according tothe position of the displacement member.

EXAMPLE 16

The method of one or more of Example 13 through Example 15, furthercomprising: detecting, by a closure trigger sensor, a position of aclosure trigger configured to drive the closure mechanism between afirst position and a second position; wherein the control circuitdetermines the position of the closure mechanism according to theposition of the closure trigger.

EXAMPLE 17

The method of one or more of Example 13 through Example 16, furthercomprising: detecting, by a sensor, a position of the end effectorbetween the open position and the closed position: wherein the controlcircuit determines the position of the closure mechanism according tothe position of the end effector.

EXAMPLE 18

The method of one or more of Example 13 through Example 17, furthercomprising: detecting, by a cartridge sensor, a cartridge type of thecartridge received by the end effector; and displaying, by the controlcircuit, whether the cartridge type matches an expected cartridge typeon the display.

Shaft Module Circuitry Arrangements

In a surgical sealing and stapling system, it may be useful to employ amodular design that allows a single handle assembly to attach tomultiple nozzle assemblies, and for a nozzle assembly to attach tomultiple handle assemblies. Since the nozzle assembly would include thevarious surgical instruments in the end effector, special circuitry inthe nozzle may be required to allow for instrumentation in a handleassembly to control the various functions in the end effector of themodular nozzle assembly. In addition, energy may need to be applied tothe end effector that may or may not originate from the handle assembly.For example, the handle assembly may be battery powered to control thefunctions of the handle assembly, but may not possess power sufficientto control the end effector.

In some aspects, a unique circuitry system is included in the nozzleassembly that allows for a user of the modular surgical instrumentsdescribed herein to manipulate the end effector directly from theinstrumentation contained in the handle assembly. The nozzle assemblymay include an onboard circuit board that allows for an electrosurgicalgenerator to attach directly to the nozzle assembly and supply radiofrequency (RF) energy to the end effector, while also interfacing withthe processor or control circuit of the handle assembly. In someaspects, the unique circuitry of the nozzle assembly also allows forshaft rotation while still supplying proper energy and functionality tothe end effector.

In one aspect, connecting the surgical instrument to a generator enablescertain shaft functions. For example, attachment of RF leads to thegenerator allow the surgical instrument onboard circuit board to isolatesome of the elongated shaft integral circuit wiring for RF applicationto an RF cartridge interchangeably usable with stapling cartridges. Theonboard circuit board is a segmented circuit configured to isolate thegenerator inputs (e.g., RF energy, etc.) from the handle electronicswhere appropriate. A flex circuit contains electrical conductors withdifferent geometries to accommodate RF energy transfer.

Referring to FIG. 40, in some aspects, the nozzle assembly 1240 thatconstitutes a modular portion of the surgical tool assembly 1000 mayinclude shaft module circuitry uniquely configured to control variousfunctions in the shaft assembly while also communicating with the handleassembly 500 and allowing for the RF generator 400 to be controlled fromthe powered stapling handle. In FIG. 40, the circuitry of FIG. 15 isshown in the context of an example nozzle assembly 1240. The circuitryaccording to some aspects of the present disclosures includes theonboard circuit board 1152 with various connectors. Female connectors410 are electrically coupled to the circuit board 1152, which allows forconnection with the male plug assembly 406 that couple to the generator400, not shown.

In addition, the onboard on/off power switch 420 is electrically coupledto the circuit board 1152 and positioned in such a way so as to bepressed when the nozzle assembly 1240 is attached to the handle assembly500, according to some aspects. For example, when the nozzle assemblylocks into place (see e.g., FIG. 9), the on/off power switch 420 may bepositioned to face proximally to the handle assembly and may be pressedas the nozzle assembly slides into the slot of the handle assembly viathe closure link 514 (see FIG. 9). In other cases, the on/off powerswitch 420 is exposed so that it may be manually pressed by an operatorof the surgical tool assembly 1000.

The circuit board 1152 includes the onboard connector 1154 configured tointerface with the housing connector 562 (see FIG. 9) communicating withthe microprocessor 560 contained in the handle assembly 500. In thisway, the handle assembly 500 is capable of commanding the circuit board1152 that controls several functions in the nozzle assembly 1240. Thedesign of the circuitry in the nozzle assembly 1240 allows for anoperator to perform a number of functions from the various controls ofthe handle assembly 500, such as through the various controls anddisplay consoles available in the handle assembly 500.

The circuit board 1152 also includes the proximal connector 1153 that isconfigured to interface with the slip ring assembly 1150. Power may besupplied to the end effector even while the shaft rotates due to powerbeing supplied throughout the slip ring assembly 1150 and the distalconnector 1162 being in constant contact with the slip ring assembly asthe flexible shaft circuit strip 1164 rotates within the proximalclosure tube 1910. The shaft circuit strip 1164 may include a number ofelectrical conductors, such as the narrow electrical conductors 1166 forstapling related activities and the wider electrical conductors 1168 forRF purposes (see FIG. 15).

Based on the various components described in the nozzle assembly 1240,the circuitry 1152 may be configured to control the RF generator 400from the powered handle assembly 500, allowing for communication withthe various functions and interfaces of the handle assembly 500, andallowing for operation of the RF and stapling functions of the endeffector from the handle assembly 500. Other functions may includecontrolling a type of algorithm for performing various surgicalprocedures and energy applications at the end effector, enabling warningfunctionality viewable at the handle assembly 500 of any part of thenozzle assembly 1240, and varying energy modulation from the RFgenerator 400. In some aspects, the circuit board 1152 may be programmedto facilitate these functions, while in other cases the onboardconnecter 1154 may allow for the handle assembly circuitry to beprogrammed to facilitate these functions and the circuit board 1152 isconfigured to command the end effector accordingly.

In some aspects, the onboard circuit includes the segmented RF circuit1160, which may allow for the RF energy of the generator 400 to besupplied to the flexible shaft circuit strip via the slip ring assembly(see, e.g., FIG. 15). The RF generator may be coupled to the onboardcircuit board 1152 via the RF segmented circuit 1160. The on/off powerswitch 420 may be similarly connected to the segmented RF circuit 1160.

FIG. 41 illustrates a block diagram of a surgical system 3200 programmedto communicate power and control signals with an end effector 3250according to one aspect of this disclosure. In an example aspect, thesurgical system 3200 may include a control circuit 3210 (e.g.,microprocessor 560, segmented RF circuit 1160, or distal micro-chip1740) having an electrosurgical energy control segment (or an RF energycontrol segment) 3220 and a shaft control segment 3230 (e.g., shaftsegment (Segment 5), motor circuit segment (Segment 7), or power segment(Segment 8)). The control circuit 3210 may be programed to provideelectrosurgical energy (e.g., RF energy) to electrodes in the endeffector 3250 (e.g., end effector 1500). The surgical system 3200 mayinclude one or more electrical conductors 3260 (e.g., electricalconductors 1168) used for providing the electrosurgical energy, from anelectrosurgical energy generator 3240 (e.g., RF generator 400), to theend effector 3250. The one or more electrical conductors 3260 may beelectrically connected between the end effector 3250 and the controlcircuit 3210 (e.g., the electrosurgical energy control segment 3220 andthe shaft control segment 3230).

The electrosurgical energy control segment 3220 may be programed toprovide the electrosurgical energy to the electrodes through the one ormore electrical conductors 3260. In an example aspect, the shaft controlsegment 3230 may be programed to provide and/or receive a control signalto/from the end effector 3250 (and/or the surgical tool assembly 1000,the shaft assembly 704) through the one or more electrical conductors3260. That is, the one or more electrical conductors 3260 may be usednot only for providing the electrosurgical energy to the end effector3250, but also for communicating control signals with the end effector3250. In an example aspect, at least some portions of theelectrosurgical energy control segment 3220 and the shaft controlsegment 3230 may be electrically isolated from each other.

In an example aspect, the electrosurgical energy control segment 3220may electrically isolate the one or more electrical conductors 3260 fromthe shaft control segment 3230, for example, when providing theelectrosurgical energy to the electrodes in the end effector 3250through the one or more electrical conductors 3260. In an exampleaspect, the electrosurgical energy control segment 3220 may control aswitch 3270 located between the one or more electrical conductors 3260and the shaft control segment 3230 by providing a signal through acontrol line 3280 to electrically isolate the one or more electricalconductors 3260 from the shaft control segment 3230. The switch 3270 maybe configured to switch between an open state and a closed state. Theshaft control segment 3230 and the one or more electrical conductors3260 may be electrically isolated when the switch 3270 is in the openstate, and may be in electrical communication when the switch 3270 is inthe closed state. In another example aspect, the electrosurgical energycontrol segment 3220 may electrically isolate the one or more electricalconductors 3260 from the shaft control segment 3230 in any othersuitable manner. Other configurations of the switch 3270 may enableelectrical isolation of the one or more electrical conductors 3260 fromthe shaft control segment 3230 by closing the switch 3270.

In an example aspect, the electrosurgical energy control segment 3220may electrically isolate the one or more electrical conductors 3260 fromthe shaft control segment 3230 when the control circuit 3210 detectsthat the electrosurgical energy generator 3240 is connected to theconnector 3265 (e.g., female connectors 410), for example, bycontinuously checking the connector 3265 or sensing the application ofthe electrosurgical energy. For example, when the male plug assembly 406is plugged into the female connectors 410, the electrosurgical energycontrol segment 3220 may isolate the electrical conductors 3260 from theshaft control segment 3230. In another example aspect, theelectrosurgical energy control segment 3220 may electrically isolate theone or more electrical conductors 3260 from the shaft control segment3230 when the electrosurgical energy is provided to the end effector3250 or at any other suitable moment.

In an example aspect, the surgical system may include one or moreelectrical conductors 3290 (e.g., electrical conductors 1166) used foroperating the end effector 3250 (and/or the surgical tool assembly 1000,the shaft assembly 704). In an example aspect, the one or moreelectrical conductors 3290 may not be used to deliver theelectrosurgical energy to the end effector 3250. The shaft controlsegment 3230 may be programed to provide and/or receive a control signalto/from the end effector 3250 through the one or more electricalconductors 3290. In an example aspect, the shaft control segment 3230may use the one or more electrical conductors 3290 to provide and/orreceive the control signal to/from the end effector 3250 while theswitch 3270 is in an open state (e.g., while the electrosurgical energycontrol segment 3220 is providing the electrosurgical energy to the endeffector 3250 through the one or more electrical conductors 3260). In anexample aspect, the shaft control segment 3230 also may use the one ormore electrical conductors 3290 to provide and/or receive the controlsignal to/from the end effector 3250 while the switch 3270 is in aclosed state.

The switch 3270 may be a transistor switch, a mechanical switch, or anyother suitable switch. In an example aspect, the control signalscommunicated between the control circuit 3210 and the end effector 3250(and/or the surgical tool assembly 1000, the shaft assembly 704) throughthe electrical conductors 3260, 3290 include, but are not limited to,signals for driving the end effector 3250 (and/or the surgical toolassembly 1000, the shaft assembly 704) in cutting and/or coagulationoperating modes, measuring electrical characteristics of the surgicalsystem 3200 and/or the tissue clamped in the end effector 3250,providing feedback to use, communicating sensor signals, and identifyingcertain characteristics of the end effector 3250 (e.g., used/unusedstatus).

Accordingly, aspects of the present disclosure may advantageously reducethe number of electrical conductors necessary for communicating controlsignals between the control circuit 3210 and the end effector 3250(and/or the surgical tool assembly 1000, the shaft assembly 704) byusing some of the electrical conductors (e.g., electrical conductors3260) used for the delivery of the electrosurgical energy to communicatethe control signals when those electrical conductors are not used forthe electrosurgical energy. Moreover, by isolating those electricalconductors from other circuit segments (e.g., shaft control segment3230) when providing the electrosurgical energy through those electricalconductors, aspects of the present disclosure may prevent theelectrosurgical energy from flowing into the other circuit segmentsand/or electrical conductors (e.g., electrical conductors 3290)connected to those circuit segments, preventing damages to those circuitsegments and/ore electrical conductors.

Various aspects of the subject matter described herein are set out inthe following examples:

EXAMPLE 1

A control circuit for a surgical instrument, the control circuitcomprising: a shaft control segment; an electrosurgical energy controlsegment; and a connector coupled to the electrosurgical energy controlsegment configured to couple to an electrosurgical generator; whereinthe shaft control segment is configured to: communicate with a handleportion of the surgical instrument; and receive user input controls;wherein the electrosurgical energy control segment is configured to:detect connection of the electrosurgical generator to the connector;communicate with the electrosurgical generator; electrically isolate thehandle control segment from the electrosurgical energy control segmentwhen the connection of the electrosurgical generator to the connector isdetected; and provide electrosurgical energy from the electrosurgicalgenerator to an end effector portion of the surgical instrument througha first set of electrical conductors.

EXAMPLE 2

The control circuit of Example 1, further comprising a first electricalconductor to electrically connect the control circuit to an endeffector; wherein the shaft control segment is configured to provide acontrol signal for operating the end effector to the end effectorthrough the first electrical conductor; and wherein the electrosurgicalenergy control segment is configured to provide the electrosurgicalenergy to the at least one electrode through the first electricalconductor.

EXAMPLE 3

The control circuit of Example 2, wherein the electrosurgical energycontrol segment is configured to electrically isolate the firstelectrical conductor from the shaft control segment when providing theelectrosurgical energy to at least one electrode located in the endeffector.

EXAMPLE 4

The control circuit of Example 3, further comprising a switchelectrically coupled between the electrosurgical energy control segmentand the shaft control segment, wherein the electrosurgical energycontrol segment is configured to electrically isolate the firstelectrical conductor from the shaft control segment by controlling theswitch.

EXAMPLE 5

The control circuit of Example 4, wherein the electrosurgical energycontrol segment is configured to electrically isolate the firstelectrical conductor from the shaft control segment by opening theswitch.

EXAMPLE 6

The control circuit of one or more of Example 2 through Example 5,further comprising a second electrical conductor, wherein the shaftcontrol segment is configured to provide the control signal to the endeffector through the second electrical conductor and wherein the shaftcontrol segment is configured to provide the control signal to the endeffector through the second electrical conductor when theelectrosurgical energy control segment is providing the electrosurgicalenergy to the electrode through the first electrical conductor.

EXAMPLE 7

The control circuit of one or more of Example 2 through Example 6,wherein the shaft control segment is configured to receive executableinstructions to operate the end effector.

EXAMPLE 8

The control circuit of one or more of Example 2 through Example 7,wherein the shaft control segment is configured to coordinate a staplingfunction and an energy delivery function.

EXAMPLE 9

The control circuit of one or more of Example 1 through Example 8,wherein the shaft control segment is configured to provide a warningsignal.

EXAMPLE 10

The control circuit of one or more of Example 1 through Example 9,wherein the shaft control segment is configured to transmit instructionsto an end effector.

EXAMPLE 11

The control circuit of one or more of Example 1 through Example 10,further comprising a slip ring assembly coupled to the shaft controlsegment and the electrosurgical energy control segment.

EXAMPLE 12

A nozzle assembly of a surgical system, the nozzle assembly comprising:an onboard circuit board; an onboard connector coupled to the onboardcircuit board and proximally located on the nozzle assembly, the onboardconnector configured to interface with a housing connector of a handleassembly when the nozzle assembly is attached to the handle assembly; ashaft attachment lug proximally located on the nozzle assembly andconfigured to be coupled to an attachment cradle of the handle assemblyto attach the nozzle assembly to the handle assembly; and a controlcircuit comprising: a shaft control segment; an electrosurgical energycontrol segment; and a connector coupled to the electrosurgical energycontrol segment configured to couple to an electrosurgical generator;wherein the shaft control segment is configured to: communicate with ahandle portion of the surgical instrument; and receive user inputcontrols; wherein the electrosurgical energy control segment isconfigured to: detect connection of the electrosurgical generator to theconnector; communicate with the electrosurgical generator; electricallyisolate the handle control segment from the electrosurgical energycontrol segment when the connection of the electrosurgical generator tothe connector is detected; and provide electrosurgical energy from theelectrosurgical generator to an end effector portion of the surgicalinstrument through a first set of electrical conductors; wherein thenozzle assembly is detachable from and attachable to the handleassembly.

EXAMPLE 13

The nozzle assembly of Example 12, further comprising: anelectrosurgical generator connector electrically coupled to the onboardcircuit board and configured to be coupled to a plug assembly of anelectrosurgical generator such that the onboard circuit board receiveselectrosurgical energy from the electrosurgical generator.

EXAMPLE 14

The nozzle assembly of one or more of Example 12 through Example 13,wherein the onboard circuit board is configured to transmit theelectrosurgical energy to the end effector via the one or moreelectrical conductors.

EXAMPLE 15

The nozzle assembly of one or more Example 12 through Example 14,further configured to receive instructions from a handle assembly to anend effector through an interface between a housing connector of thehandle assembly and the onboard connector of the nozzle assembly.

EXAMPLE 16

The nozzle assembly of Example 15, further configured to receive theinstructions from a microprocessor of the handle assembly through theinterface between the housing connector and the onboard connector.

EXAMPLE 17

The nozzle assembly of one or more of Example 12 through Example 16,wherein the nozzle assembly further comprises a power switchelectrically coupled to the onboard circuit board and is configured toactivate and deactivate transmission of electrosurgical energy.

EXAMPLE 18

The nozzle assembly of one or more of Example 12 through Example 17,further comprising a slip ring assembly distally located to the onboardcircuit board and configured to interface with the onboard circuitboard.

EXAMPLE 19

The nozzle assembly of Example 18, further comprising: a proximalconnector coupled to a distal end of the onboard circuit board and aproximal end of the slip ring assembly; and a distal connectorconfigured to interface with a distal end of the slip ring assembly andcoupled to the one or more electrical conductors.

EXAMPLE 20

The nozzle assembly of one or more of Example 12 through Example 19,further comprising a flexible shaft circuit strip configured to housethe one or more electrical conductors.

EXAMPLE 21

The nozzle assembly of one or more of Example 12 through Example 20,wherein the one or more electrical conductors comprises: a firstelectrical conductor configured to deliver energy to the end effectorfor stapler functionality; and a second electrical conductor configuredto deliver electrosurgical energy to the end effector forelectrosurgical functionality.

Systems and Methods for Controlling Control Circuits for IndependentEnergy Delivery Over Segmented Sections

In various open, endoscopic, and/or laparoscopic surgeries, for example,it may be desirable to coagulate, seal, and/or fuse tissue. One methodof sealing tissue relies upon the application of energy, such aselectrical energy, for example, to tissue captured or clamped within anend-effector or an end-effector assembly of a surgical instrument inorder to cause thermal effects within the tissue. Various mono-polar andbi-polar radio frequency (RF) surgical instruments and surgicaltechniques have been developed for such purposes. In general, thedelivery of RF energy to the captured tissue can elevate the temperatureof the tissue and, as a result, the energy can at least partiallydenature proteins within the tissue. Such proteins, such as collagen,for example, can be denatured into a proteinaceous amalgam thatintermixes and fuses, or seals, together as the proteins renature. Asthe treated region heals over time, this biological seal may bereabsorbed by the body's wound healing process.

In certain arrangements of a bi-polar radiofrequency (RF) surgicalinstrument, the surgical instrument can comprise opposing first andsecond jaws, wherein each jaw can comprise an electrode. In use, thetissue can be captured between the jaws such that energy can flowbetween the electrodes in the opposing jaws and through the tissuepositioned therebetween. Such instruments may have to seal many types oftissues, such as anatomic structures having walls with irregular orthick fibrous content, bundles of disparate anatomic structures, and/orsubstantially thick or thin anatomic structures.

Generally, it is difficult to provide electrosurgical energy to lowimpedance tissue continuously until welding of the tissue issubstantially completed. For example, when providing the electrosurgicalenergy to low impedance tissue, there is a point where the tissueimpedance becomes too low, acting like a short circuit so that thetissue merely draws a lot of current while providing no or littleelectrosurgical energy to the tissue. This can result in severalundesirable outcomes including, for example, incomplete tissue welding,excessive heating of the electrodes, a delay of the surgery, clinicianinconvenience or frustration, etc.

Aspects of the present disclosure may address the above noted deficiencyby controlling control circuits for an independent energy delivery oversegmented sections. In an example aspect, a surgical instrument mayinclude an end effector having a first jaw with a distal portion and aproximate portion, a second jaw that is movable relative to the firstjaw, a first set of electrodes located in the distal portion of thefirst jaw, and a second set of electrodes located in the proximateportion of the first jaw. The surgical instrument also may include acontrol circuit configured to provide electrosurgical energy (e.g., RFenergy) to the first set of electrodes and the second set of electrodes.The electrosurgical energy provided to the first set of electrodes andthe second set of electrodes may repeatedly alternate between the firstset of electrodes and the second set of electrodes at a predeterminedtime interval. For example, the electrosurgical energy may be providedto the first set of electrodes for a first period of time (e.g., 0.25seconds), to the second set of electrodes for a second period of time(e.g., 0.25 seconds) after the first period of time and, then, to thefirst set of electrodes for a third period of time (0.25 seconds), andso on. The alternation of the electrosurgical energy between the firstset of electrodes and the second set of electrodes may be repeated, forexample, until the welding of the tissue starts to complete or issubstantially completed. The alternation of the electrosurgical energyat a very short period of time interval (e.g., 0.25 seconds) between thefirst set of electrodes and the second set of electrodes may facilitatethe complete welding of low impedance tissue without excessive heatingof the electrodes or a delay of the surgery. In an example, thisalternation of the electrosurgical energy may be carried out by amicrochip in the first jaw or a processor in the body of the surgicalinstrument using the RF energy provided from a conventional RF energygenerator.

In this way, aspects of the present disclosure may enable the surgicalinstrument to provide the electrosurgical energy to the tissue havinglow impedance until the welding of the low impedance tissue issubstantially completed. Moreover, aspects of the present disclosure mayadvantageously use the microchip in the first jaw or a processor in thebody of the surgical instrument to alternate the electrosurgical energybetween the two sets of electrodes using the RF energy from aconventional RF energy generator.

FIG. 42 shows a schematic top view of a jaw 3000 in an end effector(e.g., end effector 1500) of a surgical instrument (e.g., surgicalsystem 10 or surgical tool assembly 1000) according to one aspect ofthis disclosure. The jaw 3000 may include a cartridge 3010, a flexcircuit 3020 having flex circuit contacts 3025 (e.g., exposed contacts1756), and an elongate slot 3030, within which a cutting member (e.g.,knife member 1330) is slideably receivable to cut tissue clamped withinthe end effector along a cutting line 3035. The elongate slot may extendfrom a proximate end of the jaw 3000. In an example aspect, the flexcircuit 3020 also may include a microchip (e.g., distal micro-chip 1740)and, then, the cartridge 3010 may be referred to as a smart cartridge.The jaw 3000 also may include a first set of electrodes 3040L, 3040R ina first zone 3060, and a second set of electrodes 3050L, 3050R in asecond zone 3065. In an example aspect, the first zone 3060 may belocated in a proximate portion of the jaw 3000 and the second zone 3065may be located in a distal portion of the jaw 3000. In another exampleaspect, the first zone 3060 and the second zone 3065 may be located inany other suitable places of the jaw 3000.

The first and second set of electrodes 3040L, 3040R, 3050L, 3050R may bein communication with and/or deposited on the flex circuit 3020. In anexample, the elongate slot 3030 may be disposed in the center of the jaw3000. In another example, the elongate slot 3000 may be disposed in anyother suitable places in the jaw 3000. As seen in FIG. 16, theelectrodes 3040L and 3050L may be located on the left side of theelongate slot 3030 and the electrodes 3040R and 3050R may be located onthe right side of the elongate slot 3030. In an example aspect, acontrol circuit (e.g., microprocessor 560, segmented RF circuit 1160, ordistal micro-chip 1740) may be configured to provide electrosurgicalenergy to the first set of electrodes 3040L, 3040R and the second set ofelectrodes 3050L, 3050R.

The electrosurgical energy may be in the form of radio frequency (RF)energy. RF energy is a form of electrical energy that may be in thefrequency range of 200 kilohertz (kHz) to 1 megahertz (MHz). Inapplication, an electrosurgical device can transmit low frequency RFenergy through tissue, which causes ionic agitation, or friction, ineffect resistive heating, thereby increasing the temperature of thetissue. The low operating temperatures of RF energy is useful forremoving, shrinking, or sculpting soft tissue while simultaneouslysealing blood vessels. RF energy works particularly well on connectivetissue, which is primarily comprised of collagen and shrinks whencontacted by heat. The first set of electrodes 3040L, 3040R and thesecond set of electrodes 3050L, 3050R may be electronically connected tothe control circuit through the flex circuit 3020. The first set ofelectrodes 3040L, 3040R and the second set of electrodes 3050L, 3050Rmay be configured to emit RF energy to form a hemostatic (or acoagulation) line on the tissue adjacent the electrodes 3040L, 3040R,3050L, 3050R along the cutting line 3035.

In an example aspect, the length 3070 of the first set of electrodes3040L, 3040R may be in the range of about 10 mm to about 100 mm,preferably in the range of about 20 mm to about 50 mm, more preferablyin the range of about 25 mm to about 35 mm. Similarly, in an exampleaspect, the length 3075 of the second set of electrodes 3050L, 3050R maybe in the range of about 10 mm to about 100 mm, preferably in the rangeof about 20 mm to about 50 mm, more preferably in the range of about 25mm to about 35 mm. In another example aspect, the first set ofelectrodes 3040L, 3040R and the second set of electrodes 3050L, 3050Rmay have any other suitable length. In an example aspect, a gap betweenthe first set of electrodes 3040L, 3040R and the second set ofelectrodes 3050L, 3050R may be very small so that the claimed tissue maybe welded from the first zone 3060 to the second zone 3065 continuouslywith no tissue located between the two zones 3060 and 3065 beingunsealed/welded. In an example aspect, the length 3072 of the gapbetween the first set of electrodes 3040L, 3040R and the second set ofelectrodes 3050L, 3050R may be in the range of about 0.1 mm to about 20mm, preferably in the range of about 0.5 mm to about 5 mm, morepreferably in the range of about 1 mm to about 3 mm. In another exampleaspect, the length 3072 of the gap between the first set of electrodes3040L, 3040R and the second set of electrodes 3050L, 3050R may have anyother suitable length. The total length 3080 of the first set ofelectrodes 3040L, 3040R, the second set of electrodes 3050L, 3050R, andthe gap may be in the range of about 20 mm to about 210 mm, preferablyin the range of about 60 mm to about 100 mm, more preferably in therange of about 50 mm to about 70 mm.

In an example aspect, the first set of electrodes 3040L, 3040R and thesecond set of electrodes 3050L, 3050R may be electrically coupled to thewider electrical conductors 1168 from which the first set of electrodes3040L, 3040R and the second set of electrodes 3050L, 3050R may receivethe electrosurgical energy (e.g., RF energy). The first set ofelectrodes 3040L, 3040R and the second set of electrodes 3050L, 3050Rmay be electronically coupled to a plurality of electrical conductors(e.g., electrical conductors 1732L and 1732R) on the flex circuit 3020through which the wider electrical conductors 1168 may provide the RFenergy to the electrodes 3040L, 3040R, 3050L, 3050R. In an exampleaspect, each of the electrodes 3040L, 3040R, 3050L, 3050R may beseparately connected to the control circuit (e.g., micro-chip 1740)through a different electrical conductor. For example, a firstelectrical conductor of the left electrical conductors 1732L may beconnected to the electrode 3040L and a second electrical conductor ofthe left electrical conductors 1732L may be connected to the electrode3050L. Similarly, a first electrical conductor of the right electricalconductors 1732R may be connected to the electrode 3040R and a secondelectrical conductor of the right electrical conductors 1732R may beconnected to the electrode 3050R.

In an example aspect, the jaw 3000 may include a multiplexer toindividually address the electrodes 3040L, 3040R, 3050L, 3050R. Themultiplexer may be included in the control circuit (e.g., microprocessor560, segmented RF circuit 1160, or distal micro-chip 1740) or locatedbetween the control circuit and the electrodes 3040L, 3040R, 3050L,3050R. The multiplexer may distribute the electrosurgical energy to theelectrodes 3040L, 3040R, 3050L, 3050R under the control of the controlcircuit. In an example aspect, the multiplexer may be configured todetect a short of the electrodes 3040L, 3040R, 3050L, 3050R, forexample, caused by a metal staple line or other electrically conductiveobject left in the tissue from a previous instrument firing or surgicalprocedure, and the electrosurgical energy could be modulated in a mannerappropriate for the short circuit. In an example aspect, the electricalconductors 1168, 1732L, 1732R may be insulated to protect components(e.g., a microchip 1740, a spine assembly 1250, laminated plates 1322, aflex circuit 3020) adjacent the electrical conductors 1168, 1732L, 1732Rfrom inadvertent RF energy. In an example aspect, the cartridge 3010 maybe interchangeable. When changing the cartridge, the narrow and widerelectrical conductors 1166, 1168 in the surgical instrument may beconnected to the new electrical conductors and electrodes in the newcartridge.

In an example aspect, the cutting member (e.g., knife member 1330) maybe directly or indirectly coupled with a motor (e.g., motor 505). Whenthe control circuit provides voltage to the motor, the cutting membermay be advanced to the first zone 3060 or the second zone 3065 to cutthe tissue in the first and second zones 3060, 3065.

FIG. 43 shows a graph 3100 depicting voltage applied to electrodes3040L, 3040R, 3050L, 3050R as a function of time in accordance with anon-limiting aspect. The pulses 3110 may represent the voltage appliedto the electrodes 3040L, 3040R in the first zone 3060. The pulses 3120may represent the voltage applied to the electrodes 3050L, 3050R in thesecond zone 3065. When the voltage is on for the first zone 3060,electrosurgical energy may be applied to the tissue adjacent to thefirst set of electrodes 3040L, 3040R to form a coagulation/welding linethere. Similarly, when the voltage is on for the second zone 3065,electrosurgical energy may be applied to the tissue adjacent to thesecond set of electrodes 3050L, 3050R to form a coagulation/welding linethere. As shown in FIG. 43, in an example aspect, the control circuitmay apply a set voltage alternatively throughout the alternation cycles.Then, the power/energy applied to the tissue may change as the tissueimpedance changes. In another example aspect, the control circuit or thegenerator 400 may change the voltage applied to the electrodes (e.g., 30volts for the first 5 cycles, 50 volts for the next 5 cycles, 80 voltsfor the next 5 cycles). In another example aspect, the control circuitor the generator 400 may change the voltage applied to the electrodes toprovide a constant power to the tissue. In this case, the voltage maychange as the tissue impedance changes.

In an example aspect, the electrosurgical energy may repeatedlyalternate between the first set of electrodes 3040L, 3040R and thesecond set of electrodes 3050L, 3050R at a predetermined time interval.For example, the electrosurgical energy may be provided to the first setof electrodes 3040L, 3040R for a first period of time (e.g., 0.25seconds) and, then, to the second set of electrodes 3050L, 3050R for asecond period of time (e.g., 0.25 seconds). Then, it may be switchedback to the first set of electrodes 3040L, 3040R and the alternation ofthe electrosurgical energy between the first set of electrodes 3040L,3040R and the second set of electrodes 3050L, 3050R may be repeated, forexample, until the impedance of the clamped tissue reaches apredetermined impedance value. In an example aspect, the predeterminedtime interval may be in the range of from about 0.05 seconds to about0.5 seconds, preferably in the range of about 0.1 seconds to about 0.4seconds, more preferably in the range of about 0.2 seconds to about 0.3seconds. In another example aspect, the predetermined time interval mayhave any other suitable time period. In an example aspect, thepredetermined time interval for the alternation of the electrosurgicalenergy may be sufficiently fast enough that the providing of theelectrosurgical energy to the first set of electrodes 3040L, 3040R andthe second set of electrodes 3050L, 3050R may appear to be simultaneous.

In an example aspect, the alternation of the electrosurgical energy maybe started once the onboard on/off power switch 420 is turned on and maycontinue the alternation without an input from a user of theelectrosurgical device until the onboard on/off power switch 420 isturned off. The onboard on/off power switch 420 may be automaticallyturned off when the measured tissue impedance reaches a predeterminedimpedance value (e.g., an impedance value indicating that the clampedtissue is completely sealed). The number of cycles (e.g., n times) ofthe alternation of the electrosurgical energy that is necessary forreaching the predetermined impedance value may vary depending on variousparameters, including tissue type, tissue thickness, how much moistureis in the tissue, etc.

In an example aspect, as shown in FIG. 43, the time interval for thefirst set of electrodes 3040L, 3040R may be the same as the timeinterval for the second set of electrodes 3050L, 3050R. In anotherexample aspect, the time interval for the first set of electrodes 3040L,3040R may be different from the time interval for the second set ofelectrodes 3050L, 3050R. For example, the time interval for the firstset of electrodes 3040L, 3040R may be 0.3 seconds, while the timeinterval for the second set of electrodes 3050L, 3050R may be 0.2seconds. That is, in this case, the electrosurgical energy may beprovided to the first set of electrodes 3040L, 3040R for 0.3 seconds,then to the second set of electrodes 3050L, 3050R for 0.2 seconds, thenrepeat this alternation. In an example aspect, the predetermined timeinterval may decrease over time. For example, the predetermined timeinterval may be 0.3 seconds in the beginning (e.g., for a couple ofcycles), 0.2 seconds after then (for the next couple of cycles), 0.1seconds after then (for the next couple of cycles before the tissuestarts to complete to weld or is welded). In another example aspect, thepredetermined time interval may increase over time.

FIG. 41 illustrates a block diagram of a surgical system 3200 programmedto communicate power and control signals with an end effector 3250according to one aspect of this disclosure. In an example aspect, thesurgical system 3200 may include a control circuit 3210 (e.g.,microprocessor 560, segmented RF circuit 1160, or distal micro-chip1740) having an electrosurgical energy control segment (or an RF energycontrol segment) 3220 and a shaft control segment 3230 (e.g., shaftsegment (Segment 5), motor circuit segment (Segment 7), or power segment(Segment 8)). The control circuit 3210 may be configured to provideelectrosurgical energy (e.g., RF energy) to the electrodes (e.g.,electrodes 3040L, 3040R, 3050L, 3050R) in the end effector 3250 (e.g.,end effector 1500). The surgical system 3200 may include one or moreelectrical conductors 3260 (e.g., electrical conductors 1168) used forproviding the electrosurgical energy, from an electrosurgical energygenerator 3240 (e.g., RF generator 400), to the effector 3250. The oneor more electrical conductors 3260 may be electrically connected betweenthe end effector 3250 and the control circuit 3210 (e.g., theelectrosurgical energy control segment 3220 and the shaft controlsegment 3230). The shaft control segment 3230 may store shaft controlprograms in a memory and controls sensors and outputs, for example.

The electrosurgical energy control segment 3220 may be configured toprovide the electrosurgical energy to the electrodes through the one ormore electrical conductors 3260. In an example aspect, the shaft controlsegment 3230 may be configured to provide and/or receive a controlsignal to/from the end effector 3250 (and/or the surgical tool assembly1000, the shaft assembly 704) through the one or more electricalconductors 3260. That is, the one or more electrical conductors 3260 maybe used not only for providing the electrosurgical energy to the endeffector 3250, but also for communicating control signals with the endeffector 3250. In an example aspect, at least some portions of theelectrosurgical energy control segment 3220 and the shaft controlsegment 3230 may be electrically isolated from each other.

In an example aspect, the electrosurgical energy control segment 3220may electrically isolate the one or more electrical conductors 3260 fromthe shaft control segment 3230, for example, when providing theelectrosurgical energy to the electrodes in the end effector 3250through the one or more electrical conductors 3260. In an exampleaspect, the electrosurgical energy control segment 3220 may control aswitch 3270 located between the one or more electrical conductors 3260and the shaft control segment 3230 by providing a signal through acontrol line 3280 to electrically isolate the one or more electricalconductors 3260 from the shaft control segment 3230. The switch 3270 maybe configured to switch between an open state and a closed state. Theshaft control segment 3230 and the one or more electrical conductors3260 may be electrically isolated when the switch 3270 is in the openstate, and may be in electrical communication when the switch 3270 is inthe closed state. In another example aspect, the electrosurgical energycontrol segment 3220 may electrically isolate the one or more electricalconductors 3260 from the shaft control segment 3230 in any othersuitable manner. Other configurations of the switch 3270 may enableelectrical isolation of the one or more electrical conductors 3260 fromthe shaft control segment 3230 by closing the switch 3270.

In an example aspect, the electrosurgical energy control segment 3220may electrically isolate the one or more electrical conductors 3260 fromthe shaft control segment 3230 when the control circuit 3210 detectsthat the electrosurgical energy generator 3240 is connected to theconnector 3265 (e.g., female connectors 410), for example, bycontinuously checking the connector 3265 or sensing the application ofthe electrosurgical energy. For example, when the male plug assembly 406is plugged into the female connectors 410, the electrosurgical energycontrol segment 3220 may isolate the electrical conductors 3260 from theshaft control segment 3230. In another example aspect, theelectrosurgical energy control segment 3220 may electrically isolate theone or more electrical conductors 3260 from the shaft control segment3230 when the electrosurgical energy is provided to the end effector3250 or at any other suitable moment.

In an example aspect, the surgical system may include one or moreelectrical conductors 3290 (e.g., electrical conductors 1166) used foroperating the end effector 3250 (and/or the surgical tool assembly 1000,the shaft assembly 704). In an example aspect, the one or moreelectrical conductors 3290 may not be used to deliver theelectrosurgical energy to the end effector 3250. The shaft controlsegment 3230 may be programmed to provide and/or receive a controlsignal to/from the end effector 3250 through the one or more electricalconductors 3290. In an example aspect, the shaft control segment 3230may use the one or more electrical conductors 3290 to provide and/orreceive the control signal to/from the end effector 3250 while theswitch 3270 is in an open state (e.g., while the electrosurgical energycontrol segment 3220 is providing the electrosurgical energy to the endeffector 3250 through the one or more electrical conductors 3260). In anexample aspect, the shaft control segment 3230 also may use the one ormore electrical conductors 3290 to provide and/or receive the controlsignal to/from the end effector 3250 while the switch 3270 is in aclosed state.

The switch 3270 may be a transistor switch, a mechanical switch,electromechanical, relay, or any other suitable switch. In an exampleaspect, the control signals communicated between the control circuit3210 and the end effector 3250 (and/or the surgical tool assembly 1000,the shaft assembly 704) through the electrical conductors 3260, 3290include, but are not limited to, signals for driving the end effector3250 (and/or the surgical tool assembly 1000, the shaft assembly 704) incutting and/or coagulation operating modes, measuring electricalcharacteristics of the surgical system 3200 and/or the tissue clamped inthe end effector 3250, providing feedback to use, communicating sensorsignals, and identifying certain characteristics of the end effector3250 (e.g., used/unused status).

Accordingly, aspects of the present disclosure may advantageously reducethe number of electrical conductors necessary for communicating controlsignals between the control circuit 3210 and the end effector 3250(and/or the surgical tool assembly 1000, the shaft assembly 704) byusing some of the electrical conductors (e.g., electrical conductors3260) used for the delivery of the electrosurgical energy to communicatethe control signals when those electrical conductors are not used forthe electrosurgical energy. Moreover, by isolating those electricalconductors from other circuit segments (e.g., shaft control segment3230) when providing the electrosurgical energy through those electricalconductors, aspects of the present disclosure may prevent theelectrosurgical energy from flowing into the other circuit segmentsand/or electrical conductors (e.g., electrical conductors 3290)connected to those circuit segments, preventing damages to those circuitsegments and/ore electrical conductors.

In an example aspect, the control circuit may include two operationmodes, Mode I and Mode II. In Mode I, the control circuit may cut thetissue when or after the welding of the tissue is completed. In Mode 2,the control circuit may cut the tissue while the welding of the tissueis in progress. Examples of these modes are described in greater detailbelow and as shown in FIGS. 44-49.

FIG. 44 is a logic flow diagram depicting a process 4500 of a controlprogram or a logic configuration for operating the surgical instrumentin accordance with Mode I. Although the example process 4500 isdescribed with reference to the logic flow diagram illustrated in FIG.44, it will be appreciated that many other methods of performing theacts associated with the method may be used. For example, the order ofsome of the blocks may be changed, certain blocks may be combined withother blocks, and some of the blocks described are optional.

In the illustrated example and with reference also to FIG. 18, a controlcircuit 610 (FIG. 18), may receive 4510 information about impedance oftissue. For example, the control circuit 610 may include an impedancefeedback circuit and measure the impedance of the tissue clamped in theend effector 602 (e.g., end effector 1500) such as, for example, thetissue adjacent the first set of electrodes 3040L, 3040R and the secondset of electrodes 3050L, 3050R. In an example aspect, the controlcircuit 610 may measure the tissue impedance periodically (e.g., every0.1 seconds, every 0.5 seconds, or every second). In another exampleaspect, the control circuit 610 may measure the tissue impedancerandomly or in any other suitable manner. The control circuit 610 mayprovide 4520 electrosurgical energy to a first set of electrodes and asecond set of electrodes, where the providing of the electrosurgicalenergy repeatedly alternates between the first set of electrodes and thesecond set of electrodes at a predetermined time interval. For example,the control circuit 610 may provide electrosurgical energy to the firstset of electrodes 3040L, 3040R and a second set of electrodes 3050L,3050R alternatively at a predetermined time interval as described abovewith regard to FIG. 43.

Then, at some points, the control circuit 610 may determine 4530 thatthe impedance of the tissue reaches a predetermined impedance value. Forexample, the predetermined impedance value may be a value indicatingthat the tissue adjacent the first set of electrodes 3040L, 3040R andthe second set of electrodes 3050L, 3050R is substantially or completelywelded or coagulated. The control circuit 610 may determine that thewelding of the tissue is substantially completed by comparing themeasured tissue impedance with the predetermined termination impedancevalue. Then, the control circuit 610 may stop 4540 the provision of theelectrosurgical energy to the first set of electrodes and the second setof electrodes. Then, the control circuit 610 may advance 4550 a cuttingmember, such as the I-beam 614, to cut the tissue. In an example aspect,the control circuit 610 may advance the cutting member (e.g., I-beam614) to the first zone 3060 to cut the tissue in the first zone 3060and, then, to the second zone 3065 to cut the tissue in the second zone3065. In another example aspect, the control circuit 610 may cut thetissue in the first zone 3060 and the second zone 3065 at the same time.

FIG. 45 shows a graph 4600 of a tissue impedance curve 4605 as afunction of time. The tissue impedance curve 4605 may represent a changein the impedance of the tissue claimed in the end effector 1500 when thecontrol circuit 610 (FIG. 18) is operating in Mode I. As shown in FIG.45, the tissue impedance tends to follow a common “bathtub” pattern,decreasing in the beginning of the energy alternation for a first timeperiod 4625 (e.g., 0.3-1.5 seconds), reaching a minimum impedance value(Z_(M)) at a first time (t₁) 4615 and, then, increasing during a secondtime period 4630 (e.g., 0.3-1.5 seconds) as the clamped tissue is beingwelded. Then, the tissue impedance may reach a point 4610 at a secondtime (t₂) 4620, where the tissue impedance at the point 4610 is equal toa predetermined termination impedance (Z_(T)).

In the first period of time 4625, the tissue impedance drops from aninitial value and decreases, e.g., has a negative slope, until itreaches the minimum impedance value (Z_(M)) because after energy isapplied to the tissue for a certain period the moisture content of thetissue evaporates causing the tissue to dry out and causes the tissueimpedance to begin rising, e.g., positive slope, after then in thesecond period of time 4630 until the tissue impedance reaches thepredetermined termination impedance Z_(T), at which point in time theenergy to the end effector may be shut off. In an example aspect, thetissue impedance may maintain the minimum impedance Z_(M) for a certainperiod of time (e.g., 0.5-5 seconds), where the tissue impedance curve4605 almost flattens out for that period of time. If the electrosurgicalenergy (e.g., RF energy) were to be applied continuously instead ofbeing shut off at the termination impedance point 4610, the tissueimpedance may increase continuously passing the point 4610.

In an example aspect, the predetermined termination impedance (Z_(T))may correspond to a point where the tissue adjacent the electrodes3040L, 3040R, 3050L, 3050R may be substantially or completely welded soas to cut the tissue (e.g., blood vessel) without bleeding. Thepredetermined termination impedance may be stored in a memory device ofthe surgical instrument (e.g., surgical system 10 or surgical toolassembly 1000).

When the tissue impedance reaches the predetermined terminationimpedance, the control circuit may stop providing the electrosurgicalenergy to the first set of electrodes 3040L, 3040R and the second set ofelectrodes 3050L, 3050R, resulting in the sudden drop of the tissueimpedance at t₂ 4620. In an example aspect, this sudden drop of thetissue impedance may occur because the control circuit stops measuringthe tissue impedance when the provision of the electrosurgical energy isstopped. As shown in FIG. 46 depicting a graph 4650 of an example motorvoltage curve, when or after the provision of the electrosurgical energyis stopped at t₂, the control circuit may provide voltage 4660 to themotor (e.g., motor 505) to cut the tissue in the first zone 3060. Then,the control circuit also may provide voltage 4670 to the motor to cutthe tissue in the second zone 3065. As shown in FIGS. 45 and 46, in ModeI, the cutting of the clamped tissue may start during a third timeperiod 4635 after the tissue impedance reaches the predeterminedtermination impedance value (e.g., completion of the tissue welding).

FIG. 47 is a logic flow diagram depicting a process 4700 of a controlprogram or a logic configuration for operating the surgical instrumentin accordance with Mode II. Although the example process 4700 isdescribed with reference to the logic flow diagram illustrated in FIG.47, it will be appreciated that many other methods of performing theacts associated with the method may be used. For example, the order ofsome of the blocks may be changed, certain blocks may be combined withother blocks, and some of the blocks described are optional.

In the illustrated example and with reference also to FIG. 18, a controlcircuit 610 may receive 4710 information about impedance of tissue. Forexample, the control circuit 610 may measure the impedance of the tissueclamped in the end effector 602 (e.g., end effector 1500). In an exampleaspect, the control circuit 610 may measure the tissue impedanceperiodically (e.g., every 0.1 seconds, every 0.5 seconds, or everysecond). In another example aspect, the control circuit 610 may measurethe tissue impedance randomly or in any other suitable manner. Thecontrol circuit 610 may provide 4720 electrosurgical energy to a firstset of electrodes in a proximate portion of a jaw and a second set ofelectrodes in a distal portion of the jaw, where the providing of theelectrosurgical energy repeatedly alternates between the first set ofelectrodes and the second set of electrodes at a predetermined timeinterval. For example, the control circuit 610 may provideelectrosurgical energy to the first set of electrodes 3040L, 3040R andthe second set of electrodes 3050L, 3050R alternatively at apredetermined time interval as described above with regard to FIG. 43.

Then, at some points, the control circuit 610 may determine 4730 thatthe impedance of the tissue reaches a predetermined impedance value. Forexample, the predetermined impedance value may be a value indicatingthat welding of the tissue adjacent the first set of electrodes 3040L,3040R and the second set of electrodes 3050L, 3050R starts to complete.Then, the control circuit 610 may advance 4740 the cutting member suchas the I-beam 614 to cut the tissue in the proximate portion whileproviding the electrosurgical energy to the first set of electrodes andthe second set of electrodes. After cutting the tissue in the proximateportion of the jaw, the control circuit 610 may advance 4740 the cuttingmember (e.g., I-beam 614) to cut the tissue in the distal portion whileproviding the electrosurgical energy to the second set of electrodes.

In an example aspect, the control circuit 610 may advance 4750 thecutting member (e.g., I-beam 614) to cut the tissue in the distalportion while providing the electrosurgical energy to both the first setof electrodes 3040L, 3040R and the second set of electrodes 3050L,3050R. In another example aspect, the control circuit 610 may stopproviding the electrosurgical energy to the first set of electrodesafter cutting the tissue in the proximate portion, and provide theelectrosurgical energy only to the second set of electrodes whilecutting the tissue in the distal portion. In this case, the provision ofthe electrosurgical energy to the second set of electrodes 3050L, 3050Rmay still be discontinuous. For example, the electrosurgical energy maybe provided to the second set of electrodes 3050L, 3050R for a setperiod of time (e.g., 0.25 seconds) and, then, no electrosurgical energymay be provided to the second set of electrodes 3050L, 3050R for thenext set period of time (e.g., 0.25 seconds) and, then theelectrosurgical energy may be provided to the second set of electrodes3050L, 3050R for the next set period of time (e.g., 0.25 seconds). Thismay be repeated while cutting the tissue in the distal portion of thejaw (e.g., the second zone 3065).

In another example aspect, the control circuit 610 may stop providingthe electrosurgical energy to the first set of electrodes 3040L, 3040Rand the second set of electrodes 3050L, 3050R after cutting the tissuein the first zone. In this case, no electrosurgical energy may beprovided to the tissue while cutting the tissue in the second zone 3065.In an example aspect, the control circuit 610 may stop providing theelectrosurgical energy to the first set of electrodes 3040L, 3040R andthe second set of electrodes 3050L, 3050R when the tissue impedancereaches a predetermined termination impedance value while cutting thetissue in the first zone 3060 and/or the second zone 3065.

FIG. 48 shows a graph 4800 of a tissue impedance curve 4805 as afunction of time. The tissue impedance curve 4805 may represent a changein the impedance of the tissue claimed in the end effector 1500 when thecontrol circuit is operating in Mode II. As seen in FIG. 45, the tissueimpedance here also tends to follow a common “bathtub” pattern,decreasing in the beginning of the energy alternation (e.g., between thefirst set of electrodes 3040L, 3040R and the second set of electrodes3050L, 3050R) for a first time period 4835 (e.g. 0.3-1.5 seconds),reaching a minimum impedance value (Z_(M)) at a first time (t₁) 4820and, then, increasing during a second time period 4840 (e.g., 0.3-1.5seconds). As explained above, in the first period of time 4835, thetissue impedance drops from an initial value and decreases, e.g., has anegative slope, until it reaches the minimum impedance value (Z_(M))because after energy is applied to the tissue for a certain period themoisture content of the tissue evaporates causing the tissue to dry outand causes the tissue impedance to begin rising, e.g., positive slope,after then in the second period of time 4840 until the tissue impedancereaches the termination impedance Z^(T1). In an example aspect, thetissue impedance may maintain the minimum impedance for a period of time(e.g., 0.5-5 seconds), where the tissue impedance curve 4805 almostflattens out for that period of time.

In an example aspect, when the tissue impedance reaches the minimumimpedance value (Z_(M)), a rate of impedance change (e.g., decrease) maybecome approximately zero as shown in FIG. 45. The welding of theclamped tissue may start to complete at this point. In an exampleaspect, in Mode II, the control circuit may start advancing the cuttingmember when the tissue impedance reaches the minimum impedance value(Z_(M)). For example, the control circuit may determine that the tissueimpedance reaches the minimum impedance value (Z_(M)) when the rate ofimpedance change (e.g., decrease) becomes approximately zero. In anotherexample aspect, in Mode II, the control circuit may start advancing thecutting member at any other suitable time before the clamped tissue iscompletely welded. If the tissue impedance maintains the minimumimpedance for a period of time (e.g., 0.5-5 seconds), the controlcircuit may start advancing the cutting member at any suitable momentduring that period of time (e.g., in the beginning/middle/end of theflat curve).

As shown in FIG. 49, and with reference also to FIG. 18, the controlcircuit 610 may provide voltage 4860 to the motor 604 (e.g., motor 505)to cut the tissue in the first zone 3060 when or after the tissueimpedance reaches the minimum impedance value (Z_(M)) before the tissuewelding is completed. The termination impedance Z^(T1) may represent thetissue impedance at the completion of the cutting at a second time (t₂)4825. Then, the control circuit may provide voltage 4870 to the motor604 (e.g., motor 505) to cut the tissue in the second zone 3065 aftercutting the tissue in the first zone 3060. The termination impedanceZ_(T2) may represent the tissue impedance at the completion of thecutting at a third time (t₃) 4830. The impedance curve 4805 may dropnear at the second time 4825 right after the cutting of the tissue inthe first zone 3060 because the clamped tissue may be wet with somefluids (e.g., blood or any other body fluids) that are produced whilecutting the tissue in the first zone 3060. Thus, although the measuredimpedance value 4805 may appear to drop after the cutting of the tissuein the first zone 3060, the actual tissue impedance may not drop, butmay be similar to or higher than Z^(T1) throughout the third time period4845. As the moisture content of the tissue evaporates causing thetissue to dry out because of the electrosurgical energy applied to theclamped tissue during the third time period 4845, the measured impedancevalue also may increase quickly to reflect the actual tissue impedance.

In an example aspect, the control circuit 610 may consider the amount oftime required to cut the clamped tissue in the end effector 602 indetermining when to start advancing the cutting member such as theI-beam 614. For example, if it takes 1 second to cut the tissue in thefirst zone 3060, the control circuit 610 may start advancing the cuttingmember (e.g. I-beam 614) around 1 second before the tissue impedancereaches a predetermined termination impedance value (where around thistime the tissue welding is normally completed) such that the tissuewelding is substantially completed by the time the cutting of the tissuein the first zone 3060 is completed. In another example aspect, thecutting speed may be adjusted so that the tissue welding issubstantially completed by the end of the cutting. For example, if ittakes 0.5 seconds from the moment the tissue impedance reaches theminimum impedance to the moment it reaches the termination impedance(e.g., where the tissue welding is completed), the cutting speed may beadjusted so that it would take 0.5 seconds to cut the tissue in thefirst or second zones 3060, 3065.

As explained above, in an example aspect, the control circuit 610 mayprovide the electrosurgical energy to both the first set of electrodes3040L, 3040R and the second set of electrodes 3050L, 3050R while cuttingthe tissue in the second zone 3065 during the third time period 4845. Inthis case, since the clamped tissue received additional electrosurgicalenergy for the third time period 4845, the termination impedance Z_(T2)at the third time 4830 may be higher than the termination impedanceZ^(T1) at the second time 4825 as seen in FIG. 48.

In an example aspect, the control circuit 610 may stop providing theelectrosurgical energy to the first set of electrodes after cutting thetissue in the first zone 3060 and provide the electrosurgical energyonly to the second set of electrodes while cutting the tissue in thesecond zone 3065. In this case, the termination impedance of the tissuein the second zone 3065 may be higher than the termination impedance ofthe tissue in the first zone 3060 since the tissue in the second zone3065 received more electrosurgical energy for the third time period 4845than the tissue in the first zone 3060, assuming that the predeterminedtime intervals for the two sets of electrodes are the same.

The functions or processes 4500, 4700 described herein may be executedby any of the processing circuits described herein, such as the controlcircuit 700 described in connection with FIGS. 16-17, the controlcircuit 610 described in connection with FIG. 18.

Various aspects of the subject matter described herein are set out inthe following examples:

EXAMPLE 1

A surgical instrument comprising: an end effector comprising: a firstjaw comprising a distal portion and a proximate portion; a second jawthat is movable relative to the first jaw; and at least one electrode inthe first jaw; a control circuit configured to provide electrosurgicalenergy to the at least one electrode, wherein the control circuitcomprises a shaft control segment and an electrosurgical energy controlsegment; and a first electrical conductor electrically connected betweenthe end effector and the control circuit; wherein the shaft controlsegment is configured to provide a control signal for operating the endeffector to the end effector through the first electrical conductor;wherein the electrosurgical energy control segment is configured toprovide the electrosurgical energy to the at least one electrode throughthe first electrical conductor.

EXAMPLE 2

The surgical instrument of Example 1, wherein the electrosurgical energycontrol segment is electrically isolated from the shaft control segment.

EXAMPLE 3

The surgical instrument of one or more of Example 1 through Example 2,wherein the electrosurgical energy control segment is configured toelectrically isolate the first electrical conductor from the shaftcontrol segment when providing the electrosurgical energy to the atleast one electrode.

EXAMPLE 4

The surgical instrument of Example 3, further comprising a switchelectrically coupled between the electrosurgical energy control segmentand the shaft control segment, wherein the electrosurgical energycontrol segment is configured to electrically isolate the firstelectrical conductor from the shaft control segment by controlling theswitch.

EXAMPLE 5

The control circuit of Example 4, wherein the electrosurgical energycontrol segment is configured to electrically isolate a first electricalconductor from the shaft control segment by opening a switch locatedbetween the first electrical conductor and the shaft control segment.

EXAMPLE 6

The surgical instrument of one or more of Example 1 through Example 5,further comprising a second electrical conductor, wherein the shaftcontrol segment is configured to provide the control signal to the endeffector through the second electrical conductor and wherein the shaftcontrol segment is configured to provide the control signal to the endeffector through the second electrical conductor when theelectrosurgical energy control segment is providing the electrosurgicalenergy to the at least one electrode through the first electricalconductor.

EXAMPLE 7

The surgical instrument of one or more of Example 1 through Example 6,wherein the second jaw comprises an anvil.

EXAMPLE 8

The surgical instrument of one or more of Example 1 through Example 7,wherein the electrosurgical energy comprises radio frequency (RF)energy.

EXAMPLE 9

The surgical instrument of one or more of Example 1 through Example 8,wherein the at least one electrode comprises a first set of electrodeslocated in the proximate portion of the first jaw and a second set ofelectrodes located in the distal portion of the first jaw, and whereinelectrosurgical energy segment is configured to repeatedly alternateelectrosurgical energy between the first set of electrodes and thesecond set of electrodes at a predetermined time interval.

EXAMPLE 10

The surgical instrument of Example 9, further comprising a cuttingmember, wherein the first jaw and the second jaw define an elongate slottherebetween extending from the proximate portion of the first jaw andwherein the cutting member is slideably receivable within the elongateslot to cut tissue located between the first jaw and the second jaw.

EXAMPLE 11

The surgical instrument of Example 10, wherein the first set ofelectrodes comprises a first electrode and a second electrode, whereinthe first electrode is located on the left side of the elongate slot andthe second electrode is located on the right side of the elongate slot.

EXAMPLE 12

The surgical instrument of one or more of Example 10 through Example 11,wherein the second set of electrodes comprise a third electrode and afourth electrode, wherein the third electrode is located on the leftside of the elongate slot and the fourth electrode is located on theright side of the elongate slot.

EXAMPLE 13

The surgical instrument of one or more of Example 9 through Example 12,wherein the predetermined time interval comprises a first time intervalfor the first set of electrodes and a second time interval for thesecond set of electrodes, wherein the first time interval is differentfrom the second time interval.

EXAMPLE 14

The surgical instrument of one or more of Example 9 through Example 12,wherein the predetermined time interval for the alternation issufficiently fast enough that the providing of the electrosurgicalenergy to the first set of electrodes and the second set of electrodesappears to be simultaneous.

EXAMPLE 15

The surgical instrument of one or more of Example 9 through Example 14,wherein the predetermined time interval is in the range of from about0.1 to 0.5 seconds.

EXAMPLE 16

A surgical system comprising: a radio frequency (RF) energy generator; ahandle body; an end effector comprising: a first jaw comprising a distalportion and a proximate portion; a second jaw that is movable relativeto the first jaw; and at least one electrode in the first jaw; a controlcircuit configured to provide RF energy, from the RF energy generator,to the at least one electrode, wherein the control circuit comprises ashaft control segment and an RF control segment; and a first electricalconductor electrically connected between the end effector and thecontrol circuit; wherein the shaft control segment is configured toprovide a control signal for operating the end effector to the endeffector through the first electrical conductor; wherein the RF controlsegment is configured to provide the RF energy to the at least oneelectrode through the first electrical conductor.

EXAMPLE 17

The surgical system of Example 16, wherein the RF control segment iselectrically isolated from the shaft control segment.

EXAMPLE 18

The surgical system of one or more of Example 16 through Example 17,wherein the RF control segment is configured to electrically isolate thefirst electrical conductor from the shaft control segment when providingthe RF energy to the at least one electrode.

EXAMPLE 19

The surgical system of Example 18, further comprising a switchelectrically coupled between the first electrical conductor and theshaft control segment, wherein the RF control segment is configured toelectrically isolate the first electrical conductor from the shaftcontrol segment by controlling the switch.

EXAMPLE 20

The control circuit of Example 19, wherein the electrosurgical energycontrol segment is configured to electrically isolate a first electricalconductor from the shaft control segment by opening a switch locatedbetween the first electrical conductor and the shaft control segment.

EXAMPLE 21

The surgical system of one or more of Example 16 through Example 20,further comprising a second electrical conductor, wherein the shaftcontrol segment is configured to provide the control signal to the endeffector through the second electrical conductor, and wherein the shaftcontrol segment is configured to provide the control signal to the endeffector to the second electrical conductor when the RF control segmentis providing the RF energy to the at least one electrode through thefirst electrical conductor.

EXAMPLE 22

The surgical system of one or more of Example 16 through Example 21,wherein the at least one electrode comprises a first set of electrodeslocated in the proximate portion of the first jaw and a second set ofelectrodes located in the distal portion of the first jaw, and whereinelectrosurgical energy segment is configured to repeatedly alternate RFenergy between the first set of electrodes and the second set ofelectrodes at a predetermined time interval.

Flexible Circuit Arrangement for Surgical Fastening Instruments

In some aspects, an electrosurgical device may have an articulatingshaft to permit a user to adjust an angle of an end effector withrespect to a handle assembly in order to access tissues at anyorientation with respect to the user. Electrical signals exchangedbetween the end effector and the handle assembly should be unimpededregardless of the type or extent of the articulation of the shaft.

Typical electrical wires running between the handle assembly and an endeffector may become tangled and potentially severed over time due torepeated bending of the articulating shaft. Therefore, the presentdisclosure provides a flexible circuit element that may withstandrepeated shaft articulation and any other mechanical motions required tooperate the end effector of the electrosurgical device.

As depicted in FIG. 14, the flexible shaft circuit strip 1164 may bedisposed in part within the proximal closure tube 1910 and extendthrough the articulation connector 1920 into the surgical end effector1500. Similarly, the knife bar 1320 may also be disposed in part withinthe proximal closure tube 1910 and extend through the articulationconnector 1920 into the surgical end effector 1500. The flexible shaftcircuit strip 1164 may be centrally supported between the laminatedplates or bars 1322 that form the knife bar 1320. Such arrangementfacilitates sufficient flexing of the knife bar 1320 and flexible shaftcircuit strip 1164 during articulation of the end effector 1500 whileremaining sufficiently stiff so as to enable the knife member 1330 to bedistally advanced through the clamped tissue. Together, the flexibleshaft circuit strip 1164 and the laminated plates or bars 1322 that formthe knife bar 1320 may comprise a flexible assembly to permit the knifebar 1320 to reciprocate while the articulation connector 1920 is bent.

FIG. 50 depicts in greater detail an aspect of a flexible assembly 3500.In the aspect of the flexible assembly 3500 depicted in FIG. 50, theknife bar 1320 is composed of two pairs of laminated plates 1322, inwhich one pair of laminated plates 1322 is disposed along a first sideof the flexible shaft circuit strip 1164 and a second pair of laminatedplates 1322 is disposed along a second side of the flexible shaftcircuit strip 1164. Although the knife bar 1320 is disclosed as havingtwo pairs of laminated plates 1322, it may be recognized that the knifebar 1320 may be composed of any even number of laminated plates 1322 inwhich a first half of the even number of laminated plates 1322 aredisposed along a first side of the flexible shaft circuit strip 1164 anda second half of the even number of the laminated plates 1322 aredisposed along a second side of the flexible shaft circuit strip 1164.

As depicted in FIG. 10, the flexible shaft circuit strip 1164 includes adistal contact portion 1169 that may be in electrical communication witha proximal contact portion 1672 of a channel circuit 1670 disposedwithin a wall recess 1625 formed in one of the channel walls 1622 of theelongate channel 1602. Thus, the distal end of the flexible shaftcircuit strip 1164 may be in a fixed position relative to the elongatechannel 1602 of the surgical end effector 1500. As depicted in FIG. 15,a proximal end of the flexible shaft circuit strip 1164 may be inelectrical communication with a distal connector 1162 of a slip ringassembly 1150 disposed in the tool frame assembly 1200. Thus, theproximal end of the flexible shaft circuit strip 1164 may be in a fixedposition relative to the tool frame assembly 1200. As depicted in FIG.14, the flexible shaft circuit strip 1164 may thus traverse thearticulation connector 1920 and may therefore bend on articulation ofthe articulation connector 1920.

The knife bar 1320 may similarly traverse the articulation connector1920 from a proximal connection to the intermediate firing shaft portion1310 disposed in the nozzle assembly 1240 to a distal connection at theknife member 1330, as depicted in FIG. 3. The knife bar 1320 maytherefore be configured to reciprocate in order to activate the knifemember 1330 while being flexible enough to bend when the articulationconnector 1920 articulates.

It may be recognized that the reciprocating action of the knife bar 1320along the sides of the flexible shaft circuit strip 1164 may causerubbing and/or abrasion of any electrical traces or wires disposed onthe flexible shaft circuit strip 1164. The electrical traces or wiresmay comprise wider wires/conductors for RF purposes and thinner wiresfor conventional stapling purposes (for example to conduct electricalcontrol or sensing signals). Such wear may result in tears or gaps inthe electrical wires that may compromise the ability of the electricalwires to conduct electrical, including RF, signals. Consequently,additional protection of the flexible shaft circuit strip 1164 may berequired.

As depicted in FIG. 50, such protection may be provided by one or moreleaf springs 3505 disposed on opposing sides of the flexible shaftcircuit strip 1164. Each leaf spring 3505 may be disposed between a sideof the flexible shaft circuit strip 1164 and an inner side of alaminated plate 1322. The leaf springs 3505 may remain fixed withrespect to the flexible shaft circuit strip 1164, and may thereforprotect each side of the flexible shaft circuit strip 1164 from wearfrom the knife bar 1320 during deployment of the knife member 1330. Eachleaf spring 3505 may also provide physical support for the flexibleshaft circuit strip 1164. Further, each leaf spring 3505 may provide arestoring force to the flexible shaft circuit strip 1164 to return theflexible shaft circuit strip 1164 to an essentially longitudinal (orunbent) geometry once the end effector 1500 is returned to a positionco-axial with the shaft of the electrosurgical device. It may berecognized that in some aspect, the flexible assembly 3500 may alsoinclude one or more of such leaf springs 3505 in addition to theflexible shaft circuit strip 1164 and the plurality of laminated plates1322.

FIG. 51A depicts the flexible assembly 3500 disposed within anelectrosurgical device, in which the knife member 1330 is disposed at aproximal knife position 3530. FIG. 51B depicts the flexible assembly3500 disposed within the electrosurgical device, in which the knifemember 1330 is disposed at a distal knife position 3531. Although thearticulation of the shaft of the electrosurgical device is depicted in aright direction (from the perspective of a use of the device) in FIGS.51A and 51B, it should be recognized that the articulation of anelectrosurgical device shaft may also be in a left direction (from theperspective of a use of the device), with the components of the flexibleassembly 3500 suitably bent in the left direction.

FIG. 51A is similar to FIG. 14 and further points out additionaldetails. For example, a proximal end of the flexible assembly 3500 maybe stabilized within the spine assembly 1250 disposed within theproximal closure tube (1910, see FIG. 14). The distal end of theflexible assembly 2500 may be stabilized within the proximal end portion1610 of the elongate channel (1602, see FIG. 4). The distal contactportion 1169 of the flexible shaft circuit strip 1164 may be bothelectrically and physically coupled to the proximal contact portion 1672of the channel circuit (1670, see FIG. 10).

As depicted in FIG. 51A, the knife member may be located at a proximalknife position 3530. In one non-limiting aspect, the proximal knifeposition 3530 of the knife member may have a proximal knife distance(PKD), for example measured from a proximal end of the knife member to adistal end of the distal contact portion 1169 of the flexible shaftcircuit strip 1164. FIG. 51B depicts the knife member located at adistal knife position 3531. In one non-limiting aspect, the distal knifeposition 3531 of the knife member may have a distal knife distance(DKD), for example measured from a proximal end of the knife member to adistal end of the distal contact portion 1169 of the flexible shaftcircuit strip 1164. No limitation is implied regarding any explicitmeasurements of either the proximal knife distance PKD or the distalknife distance DKD. However, for the purpose of this disclosure, it maybe accepted that the distal knife distance DKD is larger than theproximal knife distance PKD. It may be recognized during the use of theelectrosurgical system that the knife member 1330 may traverse from theproximal knife position 3530 to the distal knife position 3531 or fromthe distal knife position 3531 to the proximal knife position 3530.

As disclosed above, the distal end of the flexible shaft circuit strip1164 may be in a fixed position relative to the surgical end effector1500 and the proximal end of the flexible shaft circuit strip 1164 maybe in a fixed position relative to the tool frame assembly 1200.Additionally, the leaf springs 3505 may remain in a fixed position withrespect to the flexible shaft circuit strip 1164. In one non-limitingaspect, a first leaf spring 3505 may be disposed proximate to or againsta first side of the flexible shaft circuit strip 1164, and a second leafspring 3505 may be disposed proximate to or against a second or opposingside of the flexible shaft circuit strip 1164. As the knife bar 1320moves the knife member 1330 to either the distal knife position 3531 orthe proximal knife position 3530, the laminated plates 1322 of the knifebar 1320 move in a sliding manner in a longitudinal direction withrespect to the fixed position of the flexible shaft circuit strip 1164and the leaf springs 3505.

While the knife bar 1320 is in a proximal aspect and the knife member1330 is at the proximal knife position 3530, a portion of the first pairof laminated plates 1322 may be located at a first proximal position3522 a along an outer side of a first leaf spring 3505 and a portion ofthe second pair of laminated plates 1322 may be located at a secondproximal position 3522 b along an outer side of a second leaf spring3505. In this configuration, at portion of the flexible shaft circuitstrip 1164 and a portion of the leaf springs 3505 separate thoseportions of the laminated plates 1322 located at the first proximalposition 3522 a and the second proximal position 3522 b. When the knifebar 1320 is moved distally so that the knife member 1330 is at thedistal knife position 3531, the portion of the first pair of laminatedplates 1322 located at the first proximal position 3522 a may traversein the distal direction to a first distal position 3522 c. Similarly,when the knife bar 1320 is moved distally so that the knife member 1330is at the distal knife position 3531, the portion of the second pair oflaminated plates 1322 located at the second proximal position 3522 b maytraverse in the distal direction to a second distal position 3522 d. Inthis manner at least some portion of the laminated plates 1322 move in asliding manner with respect to the leaf springs 3505.

As a result of the motion of the knife bar 1320 in the distal direction,the portion of the first pair of laminated plates in the first distalposition 3522 c and the portion of the second pair of laminated platesin the second distal position 3522 d are no longer separated by theflexible shaft circuit strip 1164 and the leaf springs 3505. Thus, aninner surface of the portion of the first pair of laminated plates inthe first distal position 3522 c may contact an inner surface of theportion of the second pair of laminated plates in the second distalposition 3522 d when the knife bar 1320 is moved in the distaldirection.

It may similarly be understood that when the knife bar 1320 is moved ina proximal direction, thereby moving the knife member 1330 from thedistal knife position 3531 to the proximal knife position 3530, theportion of the first pair of laminated plates 1322 located at the firstdistal position 3522 c may traverse in the proximal direction to thefirst proximal position 3522 a. Similarly, when the knife bar 1320 ismoved in a proximal direction, the portion of the second pair oflaminated plates 1322 located at the second distal position 3522 d maytraverse in the proximal direction to the second proximal position 3522b. As a result of the motion of the knife bar 1320 in the proximaldirection, the portion of the first pair of laminated plates in thefirst proximal position 3522 a and the portion of the second pair oflaminated plates in the second proximal position 3522 b may be separatedby the leaf springs 3505 and the flexible shaft circuit strip 1164.

FIGS. 52A and 52B depict the flexible assembly 3500 of FIGS. 51A and 51Bindependent of structures that may house the flexible assembly 3500 inan electrosurgical device. In particular, FIG. 52A depicts anunarticulated flexible assembly 3501 (dotted line) and an articulatedflexible assembly 3502 after a right articulation RA. FIG. 52B depictsthe effect of a motion of the knife bar 1320 in a distal direction DD,thereby moving the knife member 1330 from the proximal knife position3530 to the distal knife position 3531. FIG. 52B additionally depictsthe effect of a motion of the knife bar 1320 in a proximal direction PDthereby moving the knife member 1330 from the distal knife position 3531to the proximal knife position 3530.

As disclosed above with respect to FIGS. 51 and 52A, B, a flexibleassembly 3500 may include a flexible shaft circuit strip 1164 disposedbetween a pair of leaf springs 3505, and a knife bar 1320 comprising twopairs of laminated plates 1322, in which a pair of laminated plates 1322is disposed along an outer surface of each of the leaf springs 3505.Such leaf springs 3505 may provide protection of the surfaces of theflexible shaft circuit strip 1164 against abrasion and wear caused bythe reciprocating motion of the laminated plates 1322. In an alternativeaspect, the flexible assembly 3500 may lack the pair of leaf springs3505 and the laminated plates 1322 may be disposed directly against thesides of the flexible shaft circuit strip 1164. The motion of thelaminated plates 1322 against the sides of the flexible shaft circuitstrip 1164 may include such motions as disclosed above in detail withrespect to FIGS. 52A, B. Such an alternative aspect of a flexibleassembly 3500 lacking the leaf springs 3505 may find use for a flexibleassembly 3500 in which the flexible shaft circuit strip 1164 includes aprotective coating on its sides, thereby obviating the need forprotective leaf springs 3505.

It may be further recognized that the flexible assembly 3500 disclosedabove may find utility in an electrosurgical device that includes an endeffector configured to include a surgical staple/fastener cartridge, aradio frequency (RF) cartridge, or to releasably accept either asurgical staple/fastener cartridge or a radio frequency (RF) cartridge.

Disclosed above are aspects of a flexible assembly configured for usewithin an electrosurgical system comprising an articulating shaft. Theflexible assembly may span an articulation connector and include aflexible shaft circuit strip configured to bend in accordance with thebending of the articulation connector. The flexible shaft circuit stripmay be configured to permit communication of electrical signals from ahandle assembly at a proximal end of the articulating shaft to an endeffector at a distal end of the articulating shaft. The flexibleassembly may also include one or more components configured to move in atransverse manner along a longitudinal axis of the articulating shaft tocontrol one or more operations of the end effector. The flexibleassembly may further include additional components configured to supportor protect the flexible shaft circuit strip and/or the componentsconfigured to move in a transverse manner along the longitudinal axis ofthe articulating shaft.

Although a flexible assembly is described with respect to a motor drivensurgical system as depicted in FIGS. 1-15 and as disclosed above, it maybe recognized that a flexible assembly may not be limited to a surgicalsystem having the specific components or functions of such a motordriven surgical system. Such a flexible assembly may be incorporatedinto any surgical system comprising at least an articulating shafthaving a body or handle assembly at a proximal end of the articulatingshaft and an end effector at a distal end of the articulating shaft.

Thus, a flexible shaft circuit strip of a flexible assembly may beconfigured to conduct any one or more electrical signals including DCelectrical signals, AC electrical signals, digital electrical signals,analog electrical signals, RF electrical signals, or any combination orcombinations of such electrical signals. The flexible shaft circuitstrip may comprise any flexible non-conducting material on which or inwhich are disposed any number, type, or size of conducting wires ortraces. The flexible shaft circuit strip may comprise any number oflayers. The flexible shaft circuit strip may further comprise any one ormore electronic components such as discrete circuits (for example,resistors, capacitors, and inductors) or integrated circuits. Theflexible shaft circuit strip may further include protective layers tocover over the one or more conducting wires or traces, and or electroniccomponents. The flexible assembly may include one or more springs, suchas leaf springs, disposed on one or more sides of the flexible shaftcircuit strip to provide a restoring force after the surgical system isreturned from an articulated position. Alternatively, the flexible shaftcircuit strip may incorporate such leaf springs in the body of theflexible shaft circuit strip.

The components configured to move in a transverse manner along thelongitudinal axis of the articulating shaft may include any number ortype of component or components capable of both a transverse motion anda flexible bending motion. Non-limiting examples of such components mayinclude wires, bands, plates, and flexible shafts. One or more of suchcomponents configured to move in a transverse manner may be included inthe flexible assembly. Multiple components may move in a concertedmanner or may move independently. Multiple components may be disposedalong a single side of the flexible shaft circuit strip. Alternatively,some number of the multiple components may be disposed along a firstside of the flexible shaft circuit strip while a different number of themultiple components may be disposed along a second side of the flexibleshaft circuit strip. The components configured to move in a transversemanner may be operatively coupled to any movable components either in aproximal end or a distal end of the articulating shaft, withoutlimitation regarding the functions of such movable components.

The flexible assembly may also include any number or type of componentsconfigured to protect or support the flexible shaft circuit strip and/orthe components configured to move in a transverse manner. For example,additional components may include any number or type of componentconfigured to protect one or more surfaces of the flexible shaft circuitstrip including, for example, protective sheets or sheaths. Theadditional components may include a frame to support the flexible shaftcircuit strip. The additional components may further include protectiveenclosures for the components configured to move in a transverse mannersuch as cannulae.

Various aspects of the subject matter described herein are set out inthe following numbered examples:

EXAMPLE 1

A motor driven surgical system comprising: a handle assembly; and aninterchangeable surgical tool assembly, operatively coupled to thehandle assembly, comprising: a nozzle assembly; a proximal closure tubehaving a proximal end operatively coupled to a distal end of the nozzleassembly; an articulation connector having a proximal end operativelycoupled to a distal end of the proximal closure tube; a surgical endeffector comprising a first jaw and a second jaw and having a proximalend operatively coupled to a distal end of the articulation connector; aflexible shaft circuit strip disposed within at least a portion of theproximal closure tube, at least a portion of the articulation connector,and at least a portion of the surgical end effector; a knife memberslideably disposed within the surgical end effector; and a knife baroperatively connected to a proximal end of the knife member, wherein theknife bar comprises a first laminated plate disposed on a first side ofthe flexible shaft circuit strip and a second laminated plate disposedon a second side of the flexible shaft circuit strip, and wherein theknife bar is configured to reciprocate along a longitudinal axis of theproximal closure tube.

EXAMPLE 2

The motor driven surgical system of Example 1, wherein the firstlaminated plate comprises a first pair of laminated plates and thesecond laminated plate comprises a second pair of laminated plates.

EXAMPLE 3

The motor driven surgical system of one or more of Example 1 throughExample 2, wherein the first laminated plate is configured toreciprocate along the first side of the flexible shaft circuit strip andthe second laminated plate is configured to reciprocate along the secondside of the flexible shaft circuit strip.

EXAMPLE 4

The motor driven surgical system of one or more of Example 1 throughExample 3, further comprising a first leaf spring disposed between thefirst side of the flexible shaft circuit strip and the first laminatedplate, and a second leaf spring disposed between the second side of theflexible shaft circuit strip and the second laminated plate.

EXAMPLE 5

The motor driven surgical system of Example 4, wherein the firstlaminated plate is configured to reciprocate along a first side of thefirst leaf spring and the second laminated plate is configured toreciprocate along a first side of the second leaf spring.

EXAMPLE 6

The motor driven surgical system of one or more of Example 4 throughExample 5, wherein the first leaf spring and the second leaf spring aredisposed within at least a portion of the articulation connector and atleast a portion of the surgical end effector.

EXAMPLE 7

The motor driven surgical system of one or more of Example 4 throughExample 6, wherein the first leaf spring and the second leaf spring areconfigured to bend around an articulation axis transverse to alongitudinal axis of the proximal closure tube.

EXAMPLE 8

The motor driven surgical system of one or more of Example 1 throughExample 7, further comprising an elongated channel disposed within thefirst jaw, wherein the elongated channel is configured to releasablyreceive a surgical fastener cartridge.

EXAMPLE 9

The motor driven surgical system of one or more of Example 1 throughExample 8, further comprising an elongated channel disposed within thefirst jaw, wherein the elongated channel is configured to releasablyreceive a radiofrequency cartridge.

EXAMPLE 10

The motor driven surgical system of Example 9, further comprising achannel circuit disposed along an inner longitudinal side of theelongated channel, wherein the channel circuit comprises a proximalcontract portion configured to electrically couple to a distal contactportion of the flexible shaft circuit strip, and wherein the channelcircuit comprises a distal contract portion configured to electricallycouple to a flexible cartridge circuit disposed on a surface of theradiofrequency cartridge.

EXAMPLE 11

A flexible assembly for use within an articulated component of a motordriven surgical system, the flexible assembly comprising: a flexibleshaft circuit strip; and a knife bar comprising a first laminated platedisposed along a first side of the flexible shaft circuit strip and asecond laminated plate disposed along a second side of the flexibleshaft circuit strip, wherein the knife bar is configured to reciprocatealong a longitudinal axis of the flexible shaft circuit strip.

EXAMPLE 12

The flexible assembly of Example 11, wherein the flexible assembly isconfigured to bend around an articulation axis transverse to alongitudinal axis of the flexible shaft circuit strip.

EXAMPLE 13

The flexible assembly of one or more of Example 11 through Example 12,wherein the first laminated plate comprises a first pair of laminatedplates and the second laminated plate comprises a second pair oflaminated plates.

EXAMPLE 14

The flexible assembly of one or more of Example 11 through Example 13,wherein a side of a first portion of the first laminated plate isdisposed along the first side of the flexible shaft circuit strip and aside of a first portion of the second laminated plate is disposed alongthe second side of the flexible shaft circuit strip when the flexibleassembly is in a first state, and wherein the side of the first portionof the first laminated plate is disposed along the side of the firstportion of the second laminated plate when the flexible assembly is in asecond state.

EXAMPLE 15

The flexible assembly of one or more of Example 11 through Example 14,further comprising a first leaf spring disposed between the first sideof the flexible shaft circuit strip and the first laminated plate, and asecond leaf spring disposed between the second side of the flexibleshaft circuit strip and the second laminated plate.

EXAMPLE 16

The flexible assembly of Example 15, wherein the first laminated plateis configured to reciprocate along a first side of the first leaf springand the second laminated plate is configured to reciprocate along afirst side of the second leaf spring.

EXAMPLE 17

The flexible assembly of one or more of Example 15 through Example 16,wherein a side of a first portion of the first laminated plate isdisposed along a first side of the first leaf spring and a side of afirst portion of the second laminated plate is disposed along a firstside of the second leaf spring when the flexible assembly is in a firststate, and wherein the side of the first portion of the first laminatedplate is disposed along the side of the first portion of the secondlaminated plate when the flexible assembly is in a second state.

EXAMPLE 18

The flexible assembly of one or more of Example 11 through Example 17,wherein the flexible shaft circuit strip comprises a distal contactportion.

EXAMPLE 19

The flexible assembly of one or more of Example 11 through Example 18,wherein the flexible shaft circuit strip comprises a plurality of narrowwires and a plurality of wider wires.

EXAMPLE 20

The flexible assembly of Example 19, wherein the plurality of widerwires is configured to conduct a radiofrequency signal.

Surgical System Coupleable with Staple Cartridge and Radio FrequencyCartridge, and having a Plurality of Radio-Frequency Energy Return Paths

In some aspects, an electrosurgical device may be configured to induce ahemostatic seal in a tissue and/or between tissues. The hemostatic sealmay be created by a combination of an applied compressive force to thetissue and an application of electrical energy to the tissue. In someaspects of an electrosurgical device, the compressive force may besupplied by a compression of the tissue between jaw assemblies.Additionally, the electrical energy may be supplied by one or moreelectrodes disposed within or on some components of the jaw assemblies.The amount of electrical energy sufficient to effect the hemostatic sealmay depend, in part, on the thickness, density, and/or quality of tissueto be sealed.

It may be understood that an application of excessive electrical energyto a tissue may result in burning or scaring of the tissue. However, theapplication of insufficient electrical energy to a tissue may result inan ineffective hemostatic seal. Thus, a user of the electrosurgicaldevice may be required to adjust the amount of electrical energydelivered to the tissue compressed between the jaw assemblies of thedevice based on the tissue thickness, density, and quality. If a tissuecompressed between the jaw assemblies is essentially homogeneous, theuser of the electrosurgical device may use simple controls to adjust theamount of electrical energy delivered to the tissue. However, it may berecognized that some tissues for hemostatic sealing are inhomogeneous inany one or more of their thickness, density, and/or quality. As aresult, a single control for the amount of electrical energy deliveredto the tissue compressed between the jaw assemblies may result in burnedportions as well as insufficiently sealed portions of the tissue. It istherefore desirable to have an electrosurgical device that may beconfigured to deliver a variety of electrical energies to a piece oftissue compressed between the jaw assemblies.

Electrosurgical instruments apply electrosurgical energy to seal tissue.However, at times tissue may be sealed with staples delivered by astaple cartridge and at other times the tissue may be sealed by theapplication of electrosurgical energy. This requires the user toinventory two separate instruments. Therefore, it would be desirable toprovide an elongate shaft for use with a surgical stapler where aninterchangeable RF cartridge is used in place of a staple cartridge. Insituations where an interchangeable RF cartridge is used in place of astaple cartridge, the present disclosure provides various techniques forcovering select surfaces with non-conductive coatings to determine theelectrical path of radio frequency (RF) applied energy when theinterchangeable RF cartridges is used in place of the staple cartridge.

FIG. 53 is a perspective view of a surgical system 4000. The surgicalsystem 4000 is similar to the motor-driven surgical system 10 in thatthe surgical system 4000 is configured to be used in connection with theconventional surgical stapler/fastener cartridges 1400 and theradio-frequency cartridges 1700. However, the surgical system 4000 isdifferent from the motor-driven surgical system 10 in that the surgicalsystem 4000 is also configured to be used in connection withradio-frequency cartridges 4002 which are similar to but different fromthe radio-frequency cartridges 1700 and are described in more detailbelow. The surgical system 4000 is also different from the motor-drivensurgical system 10 in that the surgical system 4000 includes a firingsystem 4004 (See FIG. 56) which is similar to but different from thefiring system 1300 of the motor driven surgical system 10 and isdescribed in more detail below.

As shown in FIG. 53, the surgical system 4000 includes a handle assembly4006 and an interchangeable tool assembly 4008 coupleable to the handleassembly 4006. The handle assembly 4006 is similar or identical to thehandle assembly 500 and the interchangeable tool assembly 4008 issimilar or identical to the interchangeable tool assembly 1000. Theinterchangeable tool assembly 4008 includes an end effector 4010 whichincludes a first jaw 4012 and a second jaw 4014. The first jaw 4012includes an elongate channel 4016 which is configured to removablysupport the radio-frequency cartridge 4002. According to variousaspects, the elongate channel 4016 may also be configured to removablysupport the surgical stapler/fastener cartridge 1400 and the radiofrequency cartridge 1700. The second jaw 4014 includes an anvil 4018.The end effector 4010 is similar or identical to the end effector 1500,the first jaw 4012 is similar or identical to the first jaw 1600, thesecond jaw 4014 is similar or identical to the second jaw 1800, theelongate channel 4016 is similar or identical to the elongate channel1602 and the anvil 4018 is similar or identical to the anvil 1810.

FIG. 54 is a partial cross-section of the end effector 4010 of thesurgical system 4000 according to various aspects, showing the interfacebetween the radio-frequency cartridge 4002 and the anvil 4018 when theend effector 4010 in a fully closed position. For purposes of clarity,the elongate channel 4016 is not shown in FIG. 54. The radio-frequencycartridge 4002 is similar to the radio frequency cartridge 1700 but isdifferent in that the radio-frequency cartridge 4002 includes acartridge deck surface 4020 which defines at least two protrusions 4022.Although only one of the protrusions 4022 is shown in the cross-sectionof FIG. 54, it will be appreciated that a first one of the protrusions4022 is positioned on one side of a centrally disposed elongate slot4024 of the radio-frequency cartridge 4002 and a second one of theprotrusions 4022 is positioned on the opposite side of the centrallydisposed elongate slot 4024 of the radio-frequency cartridge 4002 (See,e.g., FIG. 55).

The radio-frequency cartridge 4002 is also different from the radiofrequency cartridge 1700 in that the radio-frequency cartridge 4002includes insulative sheath members 4026 which respectively defineprotrusions 4028 which are associated with the protrusions 4022.Although only one of the insulative sheath members 4026 and one of theprotrusions 4028 are shown in the cross-section of FIG. 54, it will beappreciated that a first one of the insulative sheath members 4026 and afirst one of the protrusions 4028 are positioned on one side of thecentrally disposed elongate slot 4024 of the radio-frequency cartridge4002, and a second one of the insulative sheath members 4026 and asecond one of the protrusions 4028 are positioned on the opposite sideof the centrally disposed elongate slot 4024 of the radio-frequencycartridge 4002 (See, e.g., FIG. 55). The protrusions 4028 are positionedbetween the protrusions 4022 of the cartridge deck surface 4020 and theanvil 4018 of the interchangeable tool assembly 4008.

The radio-frequency cartridge 4002 is also different from the radiofrequency cartridge 1700 in that the radio-frequency cartridge 4002further includes flexible circuit assemblies 4030 which respectivelydefine protrusions 4032 which are associated with the protrusions 4022and the protrusions 4028. Although only one of the flexible circuitassemblies 4030 and one of the protrusions 4032 are shown in thecross-section of FIG. 54, it will be appreciated that a first one of theflexible circuit assemblies 4030 and a first one of the protrusions 4032are positioned on one side of the centrally disposed elongate slot 4024of the radio-frequency cartridge 4002, and a second one of the flexiblecircuit assemblies 4030 and a second one of the protrusions 4032 arepositioned on the opposite side of the centrally disposed elongate slot4024 of the radio-frequency cartridge 4002 (See, e.g., FIG. 55). Theprotrusions 4032 are positioned between the protrusions 4028 and theanvil 4020 of the interchangeable tool assembly 4004. Other than theprotrusions 4022, 4028, 4032, the cartridge deck surface 4020 is similarto the cartridge deck surface 1711, the insulative sheath members 4026are similar to the insulator/sheath members 1734, and the flexiblecircuit assemblies 4030 are similar to the flexible circuit assemblies1730.

When tissue T (FIG. 6) is positioned between the radio-frequencycartridge 4002 and the anvil 4018, and the anvil 4018 is moved towardsthe radio-frequency cartridge 4002 to clamp the tissue positionedbetween the radio-frequency cartridge 4002 and the anvil 4018, theminimum gap or distance d₁ between the anvil 4018 and theradio-frequency staple cartridge 4002 proximate the distal end of theend effector 4010 is realized when the insulation material 1819positioned on the tissue facing segments 1817 of the fastener formingundersurface 1813 of the anvil 4018 is brought into physical contactwith the protrusions 4032. Once this physical contact between theinsulation material 1819 and the protrusions 4032 is established, theprotrusions 4032 physically prevent (1) the anvil 4018 from beingbrought closer to the radio-frequency cartridge 4002 and (2) the tissuefrom being further compressed. The establishment of this minimum gap ordistance d₁ also operates to help prevent the formation of an electricalshort circuit between the radio-frequency cartridge 4002 and the anvil4018.

An example of an RF cartridge that routes RF energy through tissue froman electrode to an inner surface of a staple pocket is shown in FIGS. 6and 7. Accordingly, turning briefly to FIGS. 6 and 7, there is shown apartial cross-sectional view of the end effector 1500 depicted in FIGS.1-5 supporting an RF cartridge 1700 (FIGS. 10-12), 4002 (FIGS. 53 and55) therein and with tissue T clamped between the cartridge 1400 (FIG.4) and the anvil 1810 and a partial cross-sectional view of the anvil1810. In the example illustrated in FIGS. 6 and 7, the anvil 1810comprises non-conductive masking except in pockets 1814 such that all ofthe surfaces not for staple formation are masked off and coated with anon-conductive electrically insulative material 1819 creating a varyingreturn path surface containing dimples and extension minimizing thecharring and tissue sticking experienced by flat opposed electrodes. Asshown in FIG. 6, in at least one form, the anvil 1810 includes an anvilbody portion 1812 that is fabricated from an electrically conductivemetal material for example and has a staple forming undersurface 1813that has a series of fastener forming pockets 1814 formed therein oneach side of a centrally disposed anvil slot 1815 that is configured toslidably accommodate the knife member 1330 (FIGS. 2-4, 56) therein. Theanvil slot 1815 opens into an upper opening 1816 that extendslongitudinally through the anvil body to accommodate the anvilengagement features 1336 (FIG. 4) on the knife member 1330 duringfiring. When a conventional mechanical surgical staple/fastenercartridge 1400 (FIG. 4) is installed in the elongate channel 1602 (FIG.4), the staples/fasteners are driven into forming contact with thecorresponding fastener forming pockets 1814. The anvil body 1812 mayhave an opening in the upper portion thereof to facilitate ease ofinstallation for example. An anvil cap 1818 may be inserted therein andwelded to the anvil body 1812 to enclose the opening and improve theoverall stiffness of the anvil body 1812. As shown in FIG. 7, tofacilitate use of the end effector 1500 (FIGS. 1 and 2) in connectionwith RF cartridges 1700, 4002 the tissue facing segments 1817 of thefastener forming undersurface 1813 may have electrically insulativematerial 1819 thereon. Accordingly, the features described in referenceto FIGS. 6 and 7 can be applied to the end effector 4010 (FIGS. 53 and55) and the RF cartridge 4002 (FIGS. 53-55).

FIG. 55 is a partial perspective view of the radio-frequency cartridge4002 supported by the elongate channel 4016 according to variousaspects. As described above, the radio-frequency cartridge 4002 includesflexible circuit assemblies 4030 and protrusions 4032 on each side ofthe centrally disposed elongate slot 4024. For purposes of clarity, theinsulative sheath members 4026 are not shown in FIG. 55. Additionally,it will be appreciated that the protrusions 4022, 4028 are hidden fromview in FIG. 55.

FIG. 56 is an exploded perspective assembly view of portions of thehandle assembly 4006 and the interchangeable tool assembly 4008according to various aspects. The handle assembly 4006 is similar oridentical to the handle assembly 500. The interchangeable tool assembly4008 is similar to the interchangeable tool assembly 1000, but isdifferent in that the portion of the firing system 4004 associated withthe interchangeable tool assembly 4008 is different from the portion ofthe firing system 1300 associated with the interchangeable tool system1000. The portion of the firing system 4004 associated with the handleassembly 4006 is similar or identical to the portion of the firingsystem 1300 associated with the handle assembly 500. The portion of thefiring system 4004 associated with the handle assembly 4006 includes afiring drive system 4034 which includes a longitudinal drive member4036. The longitudinal drive member 4036 has a rack of teeth 4038 formedthereon and has an attachment cradle 4040 on its distal end. The firingdrive system 4034, the longitudinal drive member 4036, the rack of teeth4038 and the attachment cradle 4040 are similar or identical to thefiring drive system 530, the longitudinal drive member 540, the rack ofteeth 542 and the attachment cradle 544 of the firing system 1300.

The portion of the firing system 4004 associated with theinterchangeable tool assembly 4008 includes a nozzle assembly 4042, anintermediate firing shaft portion 4044, a firing shaft attachment lug4046, a knife bar 4048, a firing member/knife member 4050 and a proximalclosure tube 4054 which are similar or identical to the nozzle assembly1240, the intermediate firing shaft portion 1310, the firing shaftattachment lug 1314, the knife bar 1320, the firing member/knife member1330 and the proximal closure tube 1910. However, the portion of thefiring system 4004 associated with the interchangeable tool assembly4008 is different from the portion of the firing system 1300 associatedwith the interchangeable tool assembly 1000 in that the portion of thefiring system 4004 associated with the interchangeable tool assembly4008 further includes an electrically insulative material 4056 (anelectrically non-conductive material) which operates to preventradio-frequency energy from inadvertently passing from the portion ofthe firing system 4004 associated with the interchangeable tool assembly4008 to the handle assembly 4006. In situations where radio-frequencyenergy is applied to the surgical instrument 4000, the firingmember/knife member 4050 may conduct radio-frequency energy. Without theelectrically insulative material 4056, the firing member/knife member4050 may inadvertently conduct radio-frequency energy through the knifebar 4048, through the intermediate firing shaft portion 4044 and/orthrough the firing shaft attachment lug 4046 to the portion of thefiring system 4004 associated with the handle assembly 4006.

According to various aspects, the electrically insulative material 4056is a coating which covers the firing shaft attachment lug 4046. When thefiring shaft attachment lug 4046 is seated into the attachment cradle4040 within the handle assembly 4006, electrically insulative material4056 operates to electrically isolate the longitudinal drive member 4036of the firing drive system 4034 and the handle assembly 4006 from theinterchangeable tool assembly 4008. In other words, the longitudinaldrive member 4036 and the handle assembly 4006 are protected fromreceiving inadvertent radio-frequency energy from the interchangeabletool assembly 4008. According to other aspects, the electricallyinsulative material 4056 may also cover other portions of the firingsystem 4004 to electrically isolate the longitudinal drive member 4036and the handle assembly 4006 from the interchangeable tool assembly4008. For example, the electrically insulative material 4056 may alsocover other portions of a proximal end 4058 of intermediate firing shaftportion 4044. Thus, by selectively covering various portions of thefiring system 4004 associated with the interchangeable tool assembly4008 with the electrically insulative material 4056, the conductive pathof radio-frequency energy can be designed to electrically isolate thehandle assembly 4006 from the interchangeable tool assembly 4008 forinstances where the radio-frequency cartridge 1700 or theradio-frequency cartridge 4002 is being utilized with the surgicalsystem 4000.

Various aspects of the subject matter described herein are set out inthe following numbered examples:

EXAMPLE 1

An interchangeable tool assembly, comprising: a first jaw configured tosupport a staple cartridge during a first time period and aradio-frequency cartridge during a second time period; a second jawcoupled to the first jaw, wherein a surface of the second jaw defines aplurality of staple forming pockets configured to form staples drivenfrom the staple cartridge; and an electrically insulative materialcovering segments of the surface of the second jaw other than the stapleforming pockets, wherein the staple forming pockets define at least onereturn path for radio-frequency energy delivered by the radio-frequencycartridge.

EXAMPLE 2

The interchangeable tool assembly of Example 1, wherein theinterchangeable tool assembly is configured to be releasably coupleableto a handle assembly, and wherein at least one component positionedwithin the interchangeable tool assembly comprises electrical insulationto electrically insulate the handle assembly from inadvertentradio-frequency energy from the interchangeable tool assembly.

EXAMPLE 3

The interchangeable tool assembly of one or more of Example 1 throughExample 2, wherein the interchangeable tool assembly is configured to bereleasably coupleable to a handle assembly, and wherein at least onecomponent positioned within the interchangeable tool assembly compriseselectrical insulation to electrically insulate the handle assembly frominadvertent radio-frequency energy from the interchangeable toolassembly.

EXAMPLE 4

The interchangeable tool assembly of one or more of Example 1 throughExample 3, wherein the plurality of staple forming pockets comprise: afirst plurality of staple forming pockets positioned to a first side ofa centrally disposed anvil slot; and a second plurality of stapleforming pockets positioned to a second side of the centrally disposedanvil slot.

EXAMPLE 5

The interchangeable tool assembly of one or more of Example 1 throughExample 4, wherein the plurality of staple forming pockets provide for aplurality of different return paths for radio-frequency energy deliveredby the radio-frequency cartridge.

EXAMPLE 6

The interchangeable tool assembly of one or more of Example 1 throughExample 5, wherein the segments of the surface of the second jaw facethe first jaw.

EXAMPLE 7

The interchangeable tool assembly of one or more of Example 1 throughExample 6, further comprising a firing system positioned within theinterchangeable tool assembly, wherein the firing system is configuredto couple to a handle assembly, wherein the firing system iselectrically insulated to electrically insulate the handle assembly frominadvertent radio-frequency energy.

EXAMPLE 8

The interchangeable tool assembly of one or more of Example 1 throughExample 7, further comprising a staple cartridge.

EXAMPLE 9

The interchangeable tool assembly of one or more of Example 1 throughExample 8, wherein the surgical system further comprises theradio-frequency cartridge.

EXAMPLE 10

The interchangeable tool assembly of Example 9, wherein theradio-frequency cartridge comprises at least two protrusions whichcollectively provide for a minimum gap distance between the first andsecond jaws.

EXAMPLE 11

A surgical tool assembly, comprising: an elongate channel configured tosupport a staple cartridge during a first time period and aradio-frequency cartridge during a second time period; and an anvilcoupled to the elongate channel, wherein the anvil comprises: a surfacewhich faces the elongate channel and defines a plurality of stapleforming pockets configured to form staples driven from the staplecartridge; and an electrically insulative material which covers segmentsof the surface of the second jaw, wherein the plurality of stapleforming pockets provide for a plurality of different return paths forradio-frequency energy delivered by the radio-frequency cartridge.

EXAMPLE 12

The surgical tool assembly of Example 11, wherein the elongate channeland the anvil collectively form an end effector.

EXAMPLE 13

The surgical tool assembly of one or more of Example 11 through Example12, wherein the plurality of staple forming pockets comprise: a firstplurality of staple forming pockets positioned to a first side of acentrally disposed anvil slot; and a second plurality of staple formingpockets positioned to a second side of the centrally disposed anvilslot.

EXAMPLE 14

The surgical tool assembly of one or more of Example 11 through Example13, wherein the segments of the surface of the second jaw are other thanthe staple forming pockets.

EXAMPLE 15

The surgical tool assembly of one or more of Example 11 through Example14, wherein the surgical tool assembly further comprises the staplecartridge.

EXAMPLE 16

The surgical tool assembly of one or more of Example 11 through Example15, wherein the surgical tool assembly further comprises theradio-frequency cartridge.

EXAMPLE 17

The surgical tool assembly of Example 16, wherein the radio-frequencycartridge comprises at least two protrusions which collectively providefor a minimum gap distance between the elongate channel and the anvil.

EXAMPLE 18

An interchangeable tool assembly, comprising: an end effector configuredto releasably couple to a shaft assembly, wherein the end effectorcomprises: an elongate channel configured to support a staple cartridgeduring a first time period and a radio-frequency cartridge during asecond time period; and an anvil coupled to the elongate channel,wherein the anvil comprises an electrically insulative material anddefines a plurality of different return paths for radio frequency energydelivered by the radio-frequency cartridge.

EXAMPLE 19

The interchangeable tool assembly of Example 18, wherein theelectrically insulative material faces the elongate channel.

EXAMPLE 20

The interchangeable tool assembly of one or more of Example 18 throughExample 19, further comprising the radio-frequency cartridge.

Systems and Methods for Controlling Control Circuits for an IndependentEnergy Delivery Over Segmented Sections

In various open, endoscopic, and/or laparoscopic surgeries, for example,it may be desirable to coagulate, seal, and/or fuse tissue. One methodof sealing tissue relies upon the application of energy, such aselectrical energy, for example, to tissue captured or clamped within anend-effector or an end-effector assembly of a surgical instrument inorder to cause thermal effects within the tissue. Various mono-polar andbi-polar radio frequency (RF) surgical instruments and surgicaltechniques have been developed for such purposes. In general, thedelivery of RF energy to the captured tissue can elevate the temperatureof the tissue and, as a result, the energy can at least partiallydenature proteins within the tissue. Such proteins, such as collagen,for example, can be denatured into a proteinaceous amalgam thatintermixes and fuses, or seals, together as the proteins renature. Asthe treated region heals over time, this biological seal may bereabsorbed by the body's wound healing process.

In certain arrangements of a bi-polar radio frequency (RF) surgicalinstrument, the surgical instrument can comprise opposing first andsecond jaws, wherein each jaw can comprise an electrode. In use, thetissue can be captured between the jaws such that energy can flowbetween the electrodes in the opposing jaws and through the tissuepositioned therebetween. Such instruments may have to seal many types oftissues, such as anatomic structures having walls with irregular orthick fibrous content, bundles of disparate anatomic structures, and/orsubstantially thick or thin anatomic structures.

Generally, it is difficult to provide electrosurgical energy to lowimpedance tissue continuously until welding of the tissue issubstantially completed. For example, when providing the electrosurgicalenergy to low impedance tissue, there is a point where the tissueimpedance becomes too low, acting like a short circuit so that thetissue merely draws a lot of current while providing no or littleelectrosurgical energy to the tissue. This can result in severalundesirable outcomes including, for example, incomplete tissue welding,excessive heating of the electrodes, a delay of the surgery, clinicianinconvenience or frustration, etc.

Aspects of the present disclosure may address the above noted deficiencyby controlling control circuits for an independent energy delivery oversegmented sections. In an example aspect, a surgical instrument mayinclude an end effector having a first jaw with a distal portion and aproximate portion, a second jaw that is movable relative to the firstjaw, a first set of electrodes located in the distal portion of thefirst jaw, and a second set of electrodes located in the proximateportion of the first jaw. The surgical instrument also may include acontrol circuit programed to provide electrosurgical energy (e.g., RFenergy) to the first set of electrodes and the second set of electrodes.The electrosurgical energy provided to the first set of electrodes andthe second set of electrodes may repeatedly alternate between the firstset of electrodes and the second set of electrodes at a predeterminedtime interval. For example, the electrosurgical energy may be providedto the first set of electrodes for a first period of time (e.g., 0.25seconds), to the second set of electrodes for a second period of time(e.g., 0.25 seconds) after the first period of time and, then, to thefirst set of electrodes for a third period of time (0.25 seconds), andso on. The alternation of the electrosurgical energy between the firstset of electrodes and the second set of electrodes may be repeated, forexample, until the welding of the tissue starts to complete or issubstantially completed. The alternation of the electrosurgical energyat a very short period of time interval (e.g., 0.25 seconds) between thefirst set of electrodes and the second set of electrodes may facilitatethe complete welding of low impedance tissue without excessive heatingof the electrodes or a delay of the surgery. In an example, thisalternation of the electrosurgical energy may be carried out by amicrochip in the first jaw or a processor in the body of the surgicalinstrument using the RF energy provided from a conventional RF energygenerator.

In this way, aspects of the present disclosure may enable the surgicalinstrument to provide the electrosurgical energy to the tissue havinglow impedance until the welding of the low impedance tissue issubstantially completed. Moreover, aspects of the present disclosure mayadvantageously use the microchip in the first jaw or a processor in thebody of the surgical instrument to alternate the electrosurgical energybetween the two sets of electrodes using the RF energy from aconventional RF energy generator.

FIG. 42 shows a schematic top view of a jaw 3000 in an end effector(e.g., end effector 1500) of a surgical instrument (e.g., surgicalsystem 10 or surgical tool assembly 1000) according to one aspect ofthis disclosure. The jaw 3000 may include a cartridge 3010, a flexcircuit 3020 having flex circuit contacts 3025 (e.g., exposed contacts1756), and an elongate slot 3030, within which a cutting member (e.g.,knife member 1330) is slideably receivable to cut tissue clamped withinthe end effector along a cutting line 3035. The elongate slot may extendfrom a proximate end of the jaw 3000. In an example aspect, the flexcircuit 3020 also may include a microchip (e.g., distal micro-chip 1740)and, then, the cartridge 3010 may be referred to as a smart cartridge.The jaw 3000 also may include a first set of electrodes 3040L, 3040R ina first zone 3060, and a second set of electrodes 3050L, 3050R in asecond zone 3065. In an example aspect, the first zone 3060 may belocated in a proximate portion of the jaw 3000 and the second zone 3065may be located in a distal portion of the jaw 3000. In another exampleaspect, the first zone 3060 and the second zone 3065 may be located inany other suitable places of the jaw 3000.

The first and second set of electrodes 3040L, 3040R, 3050L, 3050R may bein communication with and/or deposited on the flex circuit 3020. In anexample, the elongate slot 3030 may be disposed in the center of the jaw3000. In another example, the elongate slot 3000 may be disposed in anyother suitable places in the jaw 3000. As seen in FIG. 42, theelectrodes 3040L and 3050L may be located on the left side of theelongate slot 3030 and the electrodes 3040R and 3050R may be located onthe right side of the elongate slot 3030. In an example aspect, acontrol circuit (e.g., microprocessor 560, segmented RF circuit 1160, ordistal micro-chip 1740) may be configured to provide electrosurgicalenergy to the first set of electrodes 3040L, 3040R and the second set ofelectrodes 3050L, 3050R.

The electrosurgical energy may be in the form of radio frequency (RF)energy. RF energy is a form of electrical energy that may be in thefrequency range of 200 kilohertz (kHz) to 1 megahertz (MHz). Inapplication, an electrosurgical device can transmit low frequency RFenergy through tissue, which causes ionic agitation, or friction, ineffect resistive heating, thereby increasing the temperature of thetissue. The low operating temperatures of RF energy is useful forremoving, shrinking, or sculpting soft tissue while simultaneouslysealing blood vessels. RF energy works particularly well on connectivetissue, which is primarily comprised of collagen and shrinks whencontacted by heat. The first set of electrodes 3040L, 3040R and thesecond set of electrodes 3050L, 3050R may be electronically connected tothe control circuit through the flex circuit 3020. The first set ofelectrodes 3040L, 3040R and the second set of electrodes 3050L, 3050Rmay be configured to emit RF energy to form a hemostatic (or acoagulation) line on the tissue adjacent the electrodes 3040L, 3040R,3050L, 3050R along the cutting line 3035.

In an example aspect, the length 3070 of the first set of electrodes3040L, 3040R may be in the range of about 10 mm to about 100 mm,preferably in the range of about 20 mm to about 50 mm, more preferablyin the range of about 25 mm to about 35 mm. Similarly, in an exampleaspect, the length 3075 of the second set of electrodes 3050L, 3050R maybe in the range of about 10 mm to about 100 mm, preferably in the rangeof about 20 mm to about 50 mm, more preferably in the range of about 25mm to about 35 mm. In another example aspect, the first set ofelectrodes 3040L, 3040R and the second set of electrodes 3050L, 3050Rmay have any other suitable length. In an example aspect, a gap betweenthe first set of electrodes 3040L, 3040R and the second set ofelectrodes 3050L, 3050R may be very small so that the claimed tissue maybe welded from the first zone 3060 to the second zone 3065 continuouslywith no tissue located between the two zones 3060 and 3065 beingunsealed/welded. In an example aspect, the length 3072 of the gapbetween the first set of electrodes 3040L, 3040R and the second set ofelectrodes 3050L, 3050R may be in the range of about 0.1 mm to about 20mm, preferably in the range of about 0.5 mm to about 5 mm, morepreferably in the range of about 1 mm to about 3 mm. In another exampleaspect, the length 3072 of the gap between the first set of electrodes3040L, 3040R and the second set of electrodes 3050L, 3050R may have anyother suitable length. The total length 3080 of the first set ofelectrodes 3040L, 3040R, the second set of electrodes 3050L, 3050R, andthe gap may be in the range of about 20 mm to about 210 mm, preferablyin the range of about 60 mm to about 100 mm, more preferably in therange of about 50 mm to about 70 mm.

In an example aspect, the first set of electrodes 3040L, 3040R and thesecond set of electrodes 3050L, 3050R may be electrically coupled to thewider wires 1168 from which the first set of electrodes 3040L, 3040R andthe second set of electrodes 3050L, 3050R may receive theelectrosurgical energy (e.g., RF energy). The first set of electrodes3040L, 3040R and the second set of electrodes 3050L, 3050R may beelectronically coupled to a plurality of wires (e.g., wires 1732L and1732R) on the flex circuit 3020 through which the wider wires 1168 mayprovide the RF energy to the electrodes 3040L, 3040R, 3050L, 3050R. Inan example aspect, the wires 1168, 1732L, 1732R may be insulated toprotect components (e.g., a microchip 1740, a spine assembly 1250,laminated plates 1322, a flex circuit 3020) adjacent the wires 1168,1732L, 1732R from inadvertent RF energy. In an example aspect, thecartridge 3010 may be interchangeable. When changing the cartridge, thenarrow and wider wires 1166, 1168 in the surgical instrument may beconnected to the new wires and electrodes in the new cartridge.

In an example aspect, the cutting member (e.g., knife member 1330) maybe directly or indirectly coupled with a motor (e.g., motor 505). Whenthe control circuit provides voltage to the motor, the cutting membermay be advanced to the first zone 3060 or the second zone 3065 to cutthe tissue in the first and second zones 3060, 3065.

FIG. 43 shows a graph 3100 depicting voltage applied to electrodes3040L, 3040R, 3050L, 3050R as a function of time in accordance with anon-limiting aspect. The pulses 3110 may represent the voltage appliedto the electrodes 3040L, 3040R in the first zone 3060. The pulses 3120may represent the voltage applied to the electrodes 3050L, 3050R in thesecond zone 3065. When the voltage is on for the first zone 3060,electrosurgical energy may be applied to the tissue adjacent to thefirst set of electrodes 3040L, 3040R to form a coagulation/welding linethere. Similarly, when the voltage is on for the second zone 3065,electrosurgical energy may be applied to the tissue adjacent to thesecond set of electrodes 3050L, 3050R to form a coagulation/welding linethere. As shown in FIG. 43, in an example aspect, the control circuitmay apply a set voltage alternatively throughout the alternation cycles.Then, the power/energy applied to the tissue may change as the tissueimpedance changes. In another example aspect, the control circuit or thegenerator 400 may change the voltage applied to the electrodes (e.g., 30volts for the first 5 cycles, 50 volts for the next 5 cycles, 80 voltsfor the next 5 cycles). In another example aspect, the control circuitor the generator 400 may change the voltage applied to the electrodes toprovide a constant power to the tissue. In this case, the voltage maychange as the tissue impedance changes.

In an example aspect, the electrosurgical energy may repeatedlyalternate between the first set of electrodes 3040L, 3040R and thesecond set of electrodes 3050L, 3050R at a predetermined time interval.For example, the electrosurgical energy may be provided to the first setof electrodes 3040L, 3040R for a first period of time (e.g., 0.25seconds) and, then, to the second set of electrodes 3050L, 3050R for asecond period of time (e.g., 0.25 seconds). Then, it may be switchedback to the first set of electrodes 3040L, 3040R and the alternation ofthe electrosurgical energy between the first set of electrodes 3040L,3040R and the second set of electrodes 3050L, 3050R may be repeated, forexample, until the impedance of the clamped tissue reaches apredetermined impedance value. In an example aspect, the predeterminedtime interval may be in the range of from about 0.05 seconds to about0.5 seconds, preferably in the range of about 0.1 seconds to about 0.4seconds, more preferably in the range of about 0.2 seconds to about 0.3seconds. In another example aspect, the predetermined time interval mayhave any other suitable time period. In an example aspect, thepredetermined time interval for the alternation of the electrosurgicalenergy may be sufficiently fast enough that the providing of theelectrosurgical energy to the first set of electrodes 3040L, 3040R andthe second set of electrodes 3050L, 3050R may appear to be simultaneous.

In an example aspect, the alternation of the electrosurgical energy maybe started once the onboard on/off power switch 420 is turned on and maycontinue the alternation without an input from a user of theelectrosurgical device until the onboard on/off power switch 420 isturned off. The onboard on/off power switch 420 may be automaticallyturned off when the measured tissue impedance reaches a predeterminedimpedance value (e.g., an impedance value indicating that the clampedtissue is completely sealed). The number of cycles (e.g., n times) ofthe alternation of the electrosurgical energy that is necessary forreaching the predetermined impedance value may vary depending on variousparameters, including tissue type, tissue thickness, how much moistureis in the tissue, etc.

In an example aspect, as shown in FIG. 43, the time interval for thefirst set of electrodes 3040L, 3040R may be the same as the timeinterval for the second set of electrodes 3050L, 3050R. In anotherexample aspect, the time interval for the first set of electrodes 3040L,3040R may be different from the time interval for the second set ofelectrodes 3050L, 3050R. For example, the time interval for the firstset of electrodes 3040L, 3040R may be 0.3 seconds, while the timeinterval for the second set of electrodes 3050L, 3050R may be 0.2seconds. That is, in this case, the electrosurgical energy may beprovided to the first set of electrodes 3040L, 3040R for 0.3 seconds,then to the second set of electrodes 3050L, 3050R for 0.2 seconds, thenrepeat this alternation. In an example aspect, the predetermined timeinterval may decrease over time. For example, the predetermined timeinterval may be 0.3 seconds in the beginning (e.g., for a couple ofcycles), 0.2 seconds after then (for the next couple of cycles), 0.1seconds after then (for the next couple of cycles before the tissuestarts to complete to weld or is welded). In another example aspect, thepredetermined time interval may increase over time.

In an example aspect, the control circuit may include two operationmodes, Mode I and Mode II. In Mode I, the control circuit may cut thetissue when or after the welding of the tissue is completed. In Mode 2,the control circuit may cut the tissue while the welding of the tissueis in progress. Examples of these modes are described in greater detailbelow and as shown in FIGS. 44-49.

FIG. 41 illustrates a block diagram of a surgical system 3200 programmedto communicate power and control signals with an end effector 3250according to one aspect of this disclosure. In an example aspect, thesurgical system 3200 may include a control circuit 3210 (e.g.,microprocessor 560, segmented RF circuit 1160, or distal micro-chip1740) having an electrosurgical energy control segment (or an RF energycontrol segment) 3220 and a shaft control segment 3230 (e.g., shaftsegment (Segment 5), motor circuit segment (Segment 7), or power segment(Segment 8)). The control circuit 3210 may be programed to provideelectrosurgical energy (e.g., RF energy) to electrodes in the endeffector 3250 (e.g., end effector 1500). The surgical system 3200 mayinclude one or more electrical conductors 3260 (e.g., electricalconductors 1168) used for providing the electrosurgical energy, from anelectrosurgical energy generator 3240 (e.g., RF generator 400), to theend effector 3250. The one or more electrical conductors 3260 may beelectrically connected between the end effector 3250 and the controlcircuit 3210 (e.g., the electrosurgical energy control segment 3220 andthe shaft control segment 3230).

The electrosurgical energy control segment 3220 may be programed toprovide the electrosurgical energy to the electrodes through the one ormore electrical conductors 3260. In an example aspect, the shaft controlsegment 3230 may be programed to provide and/or receive a control signalto/from the end effector 3250 (and/or the surgical tool assembly 1000,the shaft assembly 704) through the one or more electrical conductors3260. That is, the one or more electrical conductors 3260 may be usednot only for providing the electrosurgical energy to the end effector3250, but also for communicating control signals with the end effector3250. In an example aspect, at least some portions of theelectrosurgical energy control segment 3220 and the shaft controlsegment 3230 may be electrically isolated from each other.

In an example aspect, the electrosurgical energy control segment 3220may electrically isolate the one or more electrical conductors 3260 fromthe shaft control segment 3230, for example, when providing theelectrosurgical energy to the electrodes in the end effector 3250through the one or more electrical conductors 3260. In an exampleaspect, the electrosurgical energy control segment 3220 may control aswitch 3270 located between the one or more electrical conductors 3260and the shaft control segment 3230 by providing a signal through acontrol line 3280 to electrically isolate the one or more electricalconductors 3260 from the shaft control segment 3230. The switch 3270 maybe configured to switch between an open state and a closed state. Theshaft control segment 3230 and the one or more electrical conductors3260 may be electrically isolated when the switch 3270 is in the openstate, and may be in electrical communication when the switch 3270 is inthe closed state. In another example aspect, the electrosurgical energycontrol segment 3220 may electrically isolate the one or more electricalconductors 3260 from the shaft control segment 3230 in any othersuitable manner. Other configurations of the switch 3270 may enableelectrical isolation of the one or more electrical conductors 3260 fromthe shaft control segment 3230 by closing the switch 3270.

In an example aspect, the electrosurgical energy control segment 3220may electrically isolate the one or more electrical conductors 3260 fromthe shaft control segment 3230 when the control circuit 3210 detectsthat the electrosurgical energy generator 3240 is connected to theconnector 3265 (e.g., female connectors 410), for example, bycontinuously checking the connector 3265 or sensing the application ofthe electrosurgical energy. For example, when the male plug assembly 406is plugged into the female connectors 410, the electrosurgical energycontrol segment 3220 may isolate the electrical conductors 3260 from theshaft control segment 3230. In another example aspect, theelectrosurgical energy control segment 3220 may electrically isolate theone or more electrical conductors 3260 from the shaft control segment3230 when the electrosurgical energy is provided to the end effector3250 or at any other suitable moment.

In an example aspect, the surgical system may include one or moreelectrical conductors 3290 (e.g., electrical conductors 1166) used foroperating the end effector 3250 (and/or the surgical tool assembly 1000,the shaft assembly 704). In an example aspect, the one or moreelectrical conductors 3290 may not be used to deliver theelectrosurgical energy to the end effector 3250. The shaft controlsegment 3230 may be programed to provide and/or receive a control signalto/from the end effector 3250 through the one or more electricalconductors 3290. In an example aspect, the shaft control segment 3230may use the one or more electrical conductors 3290 to provide and/orreceive the control signal to/from the end effector 3250 while theswitch 3270 is in an open state (e.g., while the electrosurgical energycontrol segment 3220 is providing the electrosurgical energy to the endeffector 3250 through the one or more electrical conductors 3260). In anexample aspect, the shaft control segment 3230 also may use the one ormore electrical conductors 3290 to provide and/or receive the controlsignal to/from the end effector 3250 while the switch 3270 is in aclosed state.

The switch 3270 may be a transistor switch, a mechanical switch, or anyother suitable switch. In an example aspect, the control signalscommunicated between the control circuit 3210 and the end effector 3250(and/or the surgical tool assembly 1000, the shaft assembly 704) throughthe electrical conductors 3260, 3290 include, but are not limited to,signals for driving the end effector 3250 (and/or the surgical toolassembly 1000, the shaft assembly 704) in cutting and/or coagulationoperating modes, measuring electrical characteristics of the surgicalsystem 3200 and/or the tissue clamped in the end effector 3250,providing feedback to use, communicating sensor signals, and identifyingcertain characteristics of the end effector 3250 (e.g., used/unusedstatus).

Accordingly, aspects of the present disclosure may advantageously reducethe number of electrical conductors necessary for communicating controlsignals between the control circuit 3210 and the end effector 3250(and/or the surgical tool assembly 1000, the shaft assembly 704) byusing some of the electrical conductors (e.g., electrical conductors3260) used for the delivery of the electrosurgical energy to communicatethe control signals when those electrical conductors are not used forthe electrosurgical energy. Moreover, by isolating those electricalconductors from other circuit segments (e.g., shaft control segment3230) when providing the electrosurgical energy through those electricalconductors, aspects of the present disclosure may prevent theelectrosurgical energy from flowing into the other circuit segmentsand/or electrical conductors (e.g., electrical conductors 3290)connected to those circuit segments, preventing damages to those circuitsegments and/ore electrical conductors.

FIG. 44 is a logic flow diagram depicting a process 4500 of a controlprogram or a logic configuration for operating the surgical instrumentin accordance with Mode I. Although the example process 4500 isdescribed with reference to the logic flow diagram illustrated in FIG.44, it will be appreciated that many other methods of performing theacts associated with the method may be used. For example, the order ofsome of the blocks may be changed, certain blocks may be combined withother blocks, and some of the blocks described are optional.

In the illustrated example and with reference also to FIG. 18, a controlcircuit 610 (FIG. 18), may receive 4510 information about impedance oftissue. For example, the control circuit 610 may include an impedancefeedback circuit and measure the impedance of the tissue clamped in theend effector 602 (e.g., end effector 1500) such as, for example, thetissue adjacent the first set of electrodes 3040L, 3040R and the secondset of electrodes 3050L, 3050R. In an example aspect, the controlcircuit 610 may measure the tissue impedance periodically (e.g., every0.1 seconds, every 0.5 seconds, or every second). In another exampleaspect, the control circuit 610 may measure the tissue impedancerandomly or in any other suitable manner. The control circuit 610 mayprovide 4520 electrosurgical energy to a first set of electrodes and asecond set of electrodes, where the providing of the electrosurgicalenergy repeatedly alternates between the first set of electrodes and thesecond set of electrodes at a predetermined time interval. For example,the control circuit 610 may provide electrosurgical energy to the firstset of electrodes 3040L, 3040R and a second set of electrodes 3050L,3050R alternatively at a predetermined time interval as described abovewith regard to FIG. 43.

Then, at some points, the control circuit 610 may determine 4530 thatthe impedance of the tissue reaches a predetermined impedance value. Forexample, the predetermined impedance value may be a value indicatingthat the tissue adjacent the first set of electrodes 3040L, 3040R andthe second set of electrodes 3050L, 3050R is substantially or completelywelded or coagulated. The control circuit 610 may determine that thewelding of the tissue is substantially completed by comparing themeasured tissue impedance with the predetermined termination impedancevalue. Then, the control circuit 610 may stop 4540 the provision of theelectrosurgical energy to the first set of electrodes and the second setof electrodes. Then, the control circuit 610 may advance 4550 a cuttingmember, such as the I-beam 614, to cut the tissue. In an example aspect,the control circuit 610 may advance the cutting member (e.g., I-beam614) to the first zone 3060 to cut the tissue in the first zone 3060and, then, to the second zone 3065 to cut the tissue in the second zone3065. In another example aspect, the control circuit 610 may cut thetissue in the first zone 3060 and the second zone 3065 at the same time.

FIG. 45 shows a graph 4600 of a tissue impedance curve 4605 as afunction of time. The tissue impedance curve 4605 may represent a changein the impedance of the tissue claimed in the end effector 1500 when thecontrol circuit 610 (FIG. 18) is operating in Mode I. As shown in FIG.45, the tissue impedance tends to follow a common “bathtub” pattern,decreasing in the beginning of the energy alternation for a first timeperiod 4625 (e.g., 0.3-1.5 seconds), reaching a minimum impedance value(Z_(M)) at a first time (t₁) 4615 and, then, increasing during a secondtime period 4630 (e.g., 0.3-1.5 seconds) as the clamped tissue is beingwelded. Then, the tissue impedance may reach a point 4610 at a secondtime (t₂) 4620, where the tissue impedance at the point 4610 is equal toa predetermined termination impedance (Z_(T)).

In the first period of time 4625, the tissue impedance drops from aninitial value and decreases, e.g., has a negative slope, until itreaches the minimum impedance value (Z_(M)) because after energy isapplied to the tissue for a certain period the moisture content of thetissue evaporates causing the tissue to dry out and causes the tissueimpedance to begin rising, e.g., positive slope, after then in thesecond period of time 4630 until the tissue impedance reaches thepredetermined termination impedance Z_(T), at which point in time theenergy to the end effector may be shut off. In an example aspect, thetissue impedance may maintain the minimum impedance Z_(M) for a certainperiod of time (e.g., 0.5-5 seconds), where the tissue impedance curve4605 almost flattens out for that period of time. If the electrosurgicalenergy (e.g., RF energy) were to be applied continuously instead ofbeing shut off at the termination impedance point 4610, the tissueimpedance may increase continuously passing the point 4610.

In an example aspect, the predetermined termination impedance (Z_(T))may correspond to a point where the tissue adjacent the electrodes3040L, 3040R, 3050L, 3050R may be substantially or completely welded soas to cut the tissue (e.g., blood vessel) without bleeding. Thepredetermined termination impedance may be stored in a memory device ofthe surgical instrument (e.g., surgical system 10 or surgical toolassembly 1000).

When the tissue impedance reaches the predetermined terminationimpedance, the control circuit may stop providing the electrosurgicalenergy to the first set of electrodes 3040L, 3040R and the second set ofelectrodes 3050L, 3050R, resulting in the sudden drop of the tissueimpedance at t₂ 4620. In an example aspect, this sudden drop of thetissue impedance may occur because the control circuit stops measuringthe tissue impedance when the provision of the electrosurgical energy isstopped. As shown in FIG. 46 depicting a graph 4650 of an example motorvoltage curve, when or after the provision of the electrosurgical energyis stopped at t₂, the control circuit may provide voltage 4660 to themotor (e.g., motor 505) to cut the tissue in the first zone 3060. Then,the control circuit also may provide voltage 4670 to the motor to cutthe tissue in the second zone 3065. As shown in FIGS. 45 and 46, in ModeI, the cutting of the clamped tissue may start during a third timeperiod 4635 after the tissue impedance reaches the predeterminedtermination impedance value (e.g., completion of the tissue welding).

FIG. 47 is a logic flow diagram depicting a process 4700 of a controlprogram or a logic configuration for operating the surgical instrumentin accordance with Mode II. Although the example process 4700 isdescribed with reference to the logic flow diagram illustrated in FIG.47, it will be appreciated that many other methods of performing theacts associated with the method may be used. For example, the order ofsome of the blocks may be changed, certain blocks may be combined withother blocks, and some of the blocks described are optional.

In the illustrated example and with reference also to FIG. 18, a controlcircuit 610 may receive 4710 information about impedance of tissue. Forexample, the control circuit 610 may measure the impedance of the tissueclamped in the end effector 602 (e.g., end effector 1500). In an exampleaspect, the control circuit 610 may measure the tissue impedanceperiodically (e.g., every 0.1 seconds, every 0.5 seconds, or everysecond). In another example aspect, the control circuit 610 may measurethe tissue impedance randomly or in any other suitable manner. Thecontrol circuit 610 may provide 4720 electrosurgical energy to a firstset of electrodes in a proximate portion of a jaw and a second set ofelectrodes in a distal portion of the jaw, where the providing of theelectrosurgical energy repeatedly alternates between the first set ofelectrodes and the second set of electrodes at a predetermined timeinterval. For example, the control circuit 610 may provideelectrosurgical energy to the first set of electrodes 3040L, 3040R andthe second set of electrodes 3050L, 3050R alternatively at apredetermined time interval as described above with regard to FIG. 43.

Then, at some points, the control circuit 610 may determine 4730 thatthe impedance of the tissue reaches a predetermined impedance value. Forexample, the predetermined impedance value may be a value indicatingthat welding of the tissue adjacent the first set of electrodes 3040L,3040R and the second set of electrodes 3050L, 3050R starts to complete.Then, the control circuit 610 may advance 4740 the cutting member suchas the I-beam 614 to cut the tissue in the proximate portion whileproviding the electrosurgical energy to the first set of electrodes andthe second set of electrodes. After cutting the tissue in the proximateportion of the jaw, the control circuit 610 may advance 4740 the cuttingmember (e.g., I-beam 614) to cut the tissue in the distal portion whileproviding the electrosurgical energy to the second set of electrodes.

In an example aspect, the control circuit 610 may advance 4750 thecutting member (e.g., I-beam 614) to cut the tissue in the distalportion while providing the electrosurgical energy to both the first setof electrodes 3040L, 3040R and the second set of electrodes 3050L,3050R. In another example aspect, the control circuit 610 may stopproviding the electrosurgical energy to the first set of electrodesafter cutting the tissue in the proximate portion, and provide theelectrosurgical energy only to the second set of electrodes whilecutting the tissue in the distal portion. In this case, the provision ofthe electrosurgical energy to the second set of electrodes 3050L, 3050Rmay still be discontinuous. For example, the electrosurgical energy maybe provided to the second set of electrodes 3050L, 3050R for a setperiod of time (e.g., 0.25 seconds) and, then, no electrosurgical energymay be provided to the second set of electrodes 3050L, 3050R for thenext set period of time (e.g., 0.25 seconds) and, then theelectrosurgical energy may be provided to the second set of electrodes3050L, 3050R for the next set period of time (e.g., 0.25 seconds). Thismay be repeated while cutting the tissue in the distal portion of thejaw (e.g., the second zone 3065).

In another example aspect, the control circuit 610 may stop providingthe electrosurgical energy to the first set of electrodes 3040L, 3040Rand the second set of electrodes 3050L, 3050R after cutting the tissuein the first zone. In this case, no electrosurgical energy may beprovided to the tissue while cutting the tissue in the second zone 3065.In an example aspect, the control circuit 610 may stop providing theelectrosurgical energy to the first set of electrodes 3040L, 3040R andthe second set of electrodes 3050L, 3050R when the tissue impedancereaches a predetermined termination impedance value while cutting thetissue in the first zone 3060 and/or the second zone 3065.

FIG. 48 shows a graph 4800 of a tissue impedance curve 4805 as afunction of time. The tissue impedance curve 4805 may represent a changein the impedance of the tissue claimed in the end effector 1500 when thecontrol circuit is operating in Mode II. As seen in FIG. 48, the tissueimpedance here also tends to follow a common “bathtub” pattern,decreasing in the beginning of the energy alternation (e.g., between thefirst set of electrodes 3040L, 3040R and the second set of electrodes3050L, 3050R) for a first time period 4835 (e.g. 0.3-1.5 seconds),reaching a minimum impedance value (Z_(M)) at a first time (t₁) 4820and, then, increasing during a second time period 4840 (e.g., 0.3-1.5seconds). As explained above, in the first period of time 4835, thetissue impedance drops from an initial value and decreases, e.g., has anegative slope, until it reaches the minimum impedance value (Z_(M))because after energy is applied to the tissue for a certain period themoisture content of the tissue evaporates causing the tissue to dry outand causes the tissue impedance to begin rising, e.g., positive slope,after then in the second period of time 4840 until the tissue impedancereaches the termination impedance Z^(T1). In an example aspect, thetissue impedance may maintain the minimum impedance for a period of time(e.g., 0.5-5 seconds), where the tissue impedance curve 4805 almostflattens out for that period of time.

In an example aspect, when the tissue impedance reaches the minimumimpedance value (Z_(M)), a rate of impedance change (e.g., decrease) maybecome approximately zero as shown in FIG. 48. The welding of theclamped tissue may start to complete at this point. In an exampleaspect, in Mode II, the control circuit may start advancing the cuttingmember when the tissue impedance reaches the minimum impedance value(Z_(M)). For example, the control circuit may determine that the tissueimpedance reaches the minimum impedance value (Z_(M)) when the rate ofimpedance change (e.g., decrease) becomes approximately zero. In anotherexample aspect, in Mode II, the control circuit may start advancing thecutting member at any other suitable time before the clamped tissue iscompletely welded. If the tissue impedance maintains the minimumimpedance for a period of time (e.g., 0.5-5 seconds), the controlcircuit may start advancing the cutting member at any suitable momentduring that period of time (e.g., in the beginning/middle/end of theflat curve).

As shown in FIG. 49, and with reference also to FIG. 18, the controlcircuit 610 may provide voltage 4860 to the motor 604 (e.g., motor 505)to cut the tissue in the first zone 3060 when or after the tissueimpedance reaches the minimum impedance value (Z_(M)) before the tissuewelding is completed. The termination impedance Z^(T1) may represent thetissue impedance at the completion of the cutting at a second time (t₂)4825. Then, the control circuit may provide voltage 4870 to the motor604 (e.g., motor 505) to cut the tissue in the second zone 3065 aftercutting the tissue in the first zone 3060. The termination impedanceZ_(T2) may represent the tissue impedance at the completion of thecutting at a third time (t₃) 4830. The impedance curve 4805 may dropnear at the second time 4825 right after the cutting of the tissue inthe first zone 3060 because the clamped tissue may be wet with somefluids (e.g., blood or any other body fluids) that are produced whilecutting the tissue in the first zone 3060. Thus, although the measuredimpedance value 4805 may appear to drop after the cutting of the tissuein the first zone 3060, the actual tissue impedance may not drop, butmay be similar to or higher than Z^(T1) throughout the third time period4845. As the moisture content of the tissue evaporates causing thetissue to dry out because of the electrosurgical energy applied to theclamped tissue during the third time period 4845, the measured impedancevalue also may increase quickly to reflect the actual tissue impedance.

In an example aspect, the control circuit 610 may consider the amount oftime required to cut the clamped tissue in the end effector 602 indetermining when to start advancing the cutting member such as theI-beam 614. For example, if it takes 1 second to cut the tissue in thefirst zone 3060, the control circuit 610 may start advancing the cuttingmember (e.g. I-beam 614) around 1 second before the tissue impedancereaches a predetermined termination impedance value (where around thistime the tissue welding is normally completed) such that the tissuewelding is substantially completed by the time the cutting of the tissuein the first zone 3060 is completed. In another example aspect, thecutting speed may be adjusted so that the tissue welding issubstantially completed by the end of the cutting. For example, if ittakes 0.5 seconds from the moment the tissue impedance reaches theminimum impedance to the moment it reaches the termination impedance(e.g., where the tissue welding is completed), the cutting speed may beadjusted so that it would take 0.5 seconds to cut the tissue in thefirst or second zones 3060, 3065.

As explained above, in an example aspect, the control circuit 610 mayprovide the electrosurgical energy to both the first set of electrodes3040L, 3040R and the second set of electrodes 3050L, 3050R while cuttingthe tissue in the second zone 3065 during the third time period 4845. Inthis case, since the clamped tissue received additional electrosurgicalenergy for the third time period 4845, the termination impedance Z_(T2)at the third time 4830 may be higher than the termination impedanceZ^(T1) at the second time 4825 as seen in FIG. 48.

In an example aspect, the control circuit 610 may stop providing theelectrosurgical energy to the first set of electrodes after cutting thetissue in the first zone 3060 and provide the electrosurgical energyonly to the second set of electrodes while cutting the tissue in thesecond zone 3065. In this case, the termination impedance of the tissuein the second zone 3065 may be higher than the termination impedance ofthe tissue in the first zone 3060 since the tissue in the second zone3065 received more electrosurgical energy for the third time period 4845than the tissue in the first zone 3060, assuming that the predeterminedtime intervals for the two sets of electrodes are the same.

The functions or processes 4500, 4700 described herein may be executedby any of the processing circuits described herein, such as the controlcircuit 700 described in connection with FIGS. 16-17, the controlcircuit 610 described in connection with FIG. 18.

Various aspects of the subject matter described herein are set out inthe following numbered examples:

EXAMPLE 1

A surgical instrument comprising: an end effector comprising: a firstjaw and a second jaw, wherein the first jaw includes a proximate portionand a distal portion and the second jaw is movable relative to the firstjaw; a first set of electrodes and a second set of electrodes, whereinthe first set of electrodes are located in a proximate portion of thefirst jaw and the second set of electrodes are located in a distalportion of the first jaw; and a slot defined between the first set ofelectrodes and the second set of electrodes; a cutting member configuredto reciprocate within the slot; and a control circuit configured to:receive information about impedance of tissue located between the firstjaw and the second jaw of the end effector; provide electrosurgicalenergy to the first set of electrodes and the second set of electrodesand repeatedly alternate the electrosurgical energy between the firstset of electrodes and the second set of electrodes at a predeterminedtime interval; and advance the cutting member.

EXAMPLE 2

The surgical instrument of Example 1, wherein the control circuit isconfigured to advance the cutting member to the proximate portion to cutthe tissue in the proximate portion after or when welding of the tissueis substantially completed.

EXAMPLE 3

The surgical instrument of Example 2, wherein the control circuit isconfigured to stop providing the electrosurgical energy to the first setof electrodes and the second set of electrodes before advancing thecutting member to the proximate portion.

EXAMPLE 4

The surgical instrument of one or more of Example 2 through Example 3,wherein the control circuit is configured to advance the cutting memberto the distal portion to cut the tissue in the distal portion aftercutting the tissue in the proximate portion.

EXAMPLE 5

The surgical instrument of one or more of Example 2 through Example 4,wherein the control circuit is configured to determine that the weldingof the tissue is substantially completed by comparing the informationabout the impedance of the tissue with a predetermined terminationimpedance value.

EXAMPLE 6

The surgical instrument of one or more of Example 1 through Example 5,wherein the control circuit is configured to advance the cutting memberto the proximate portion to cut the tissue in the proximate portionbefore welding of the tissue in the proximate portion is completed whileproviding the electrosurgical energy to the first set of electrodes andthe second set of electrodes.

EXAMPLE 7

The surgical instrument of Example 6, wherein the control circuit isconfigured to advance the cutting member to the proximate portion to cutthe tissue in the proximate portion when the welding of the tissuestarts to complete.

EXAMPLE 8

The surgical instrument of Example 7, wherein the control circuit isconfigured to determine that the welding of the tissue starts tocomplete when a rate of impedance decrease becomes approximately zero.

EXAMPLE 9

The surgical instrument of one or more of Example 6 through Example 8,wherein the control circuit is configured to advance the cutting memberto the distal portion to cut the tissue in the distal portion aftercutting the tissue in the proximate portion while providing theelectrosurgical energy to the second set of electrodes.

EXAMPLE 10

The surgical instrument of one or more of Example 1 through Example 9,wherein the predetermined time interval is in the range of from about0.1 to 0.5 seconds.

EXAMPLE 11

The surgical instrument of one or more of Example 1 through Example 10,wherein the electrosurgical energy comprises radio frequency energy.

EXAMPLE 12

A surgical instrument comprising: an end effector comprising: a firstjaw comprising a proximate portion and a distal portion; a second jawthat is movable relative to the first jaw; a first set of electrodeslocated in the proximate portion of the first jaw; and a second set ofelectrodes located in the distal portion of the first jaw; a cuttingmember, wherein the first jaw and the second jaw define an elongate slottherebetween extending from a proximate end of the first jaw and whereinthe cutting member is slideably receivable within the elongate slot tocut tissue located between the first jaw and the second jaw; a controlcircuit configured to provide electrosurgical energy to the first set ofelectrodes and the second set of electrodes, wherein the providing ofthe electrosurgical energy repeatedly alternates between the first setof electrodes and the second set of electrodes at a predetermined timeinterval, wherein the control circuit is configured to receiveinformation about impedance of the tissue located between the first jawand the second jaw.

EXAMPLE 13

The surgical instrument of Example 12, wherein the control circuit isconfigured to advance the cutting member to the proximate portion to cutthe tissue in the proximate portion after or when welding of the tissueis substantially completed.

EXAMPLE 14

The surgical instrument of Example 13, wherein the control circuit isconfigured to stop providing the electrosurgical energy to the first setof electrodes and the second set of electrodes and thereafter advancethe cutting member to the proximate portion.

EXAMPLE 15

The surgical instrument of one or more of Example 13 through Example 14,wherein the control circuit is configured to advance the cutting memberto the distal portion to cut the tissue in the distal portion and aftercutting the tissue in the proximate portion.

EXAMPLE 16

The surgical instrument of one or more of Example 13 through Example 15,wherein the control circuit is configured to determine that the weldingof the tissue is substantially completed and to compare the informationabout the impedance of the tissue with a predetermined terminationimpedance value.

EXAMPLE 17

The surgical instrument of one or more of Example 12 through Example 16,wherein the control circuit is configured to advance the cutting memberto the proximate portion to cut the tissue in the proximate portionbefore welding of the tissue in the proximate portion is completed andprovide the electrosurgical energy to the first set of electrodes andthe second set of electrodes.

EXAMPLE 18

The surgical instrument of Example 17, wherein the control circuit isconfigured to advance the cutting member to the proximate portion to cutthe tissue in the proximate portion when the welding of the tissuestarts to complete.

EXAMPLE 19

The surgical instrument of Example 18, wherein the control circuit isconfigured to determine that the welding of the tissue starts tocomplete when a rate of impedance decrease becomes approximately zero.

EXAMPLE 20

The surgical instrument of one or more of Example 17 through Example 19,wherein the control circuit is configured to advance the cutting memberto the distal portion to cut the tissue in the distal portion aftercutting the tissue in the proximate portion and simultaneously providethe electrosurgical energy to the second set of electrodes.

Surgical End Effector for Applying Electrosurgical Energy to DifferentElectrodes on Different Time Periods

In some aspects, an electrosurgical device may be configured to induce ahemostatic seal in a tissue and/or between tissues. The hemostatic sealmay be created by a combination of an applied compressive force to thetissue and an application of electrical energy to the tissue. In someaspects of an electrosurgical device, the compressive force may besupplied by a compression of the tissue between jaw assemblies.Additionally, the electrical energy may be supplied by one or moreelectrodes disposed within or on some components of the jaw assemblies.The amount of electrical energy sufficient to effect the hemostatic sealmay depend, in part, on the thickness, density, and/or quality of tissueto be sealed.

It may be understood that an application of excessive electrical energyto a tissue may result in burning or scaring of the tissue. However, theapplication of insufficient electrical energy to a tissue may result inan ineffective hemostatic seal. Thus, a user of the electrosurgicaldevice may be required to adjust the amount of electrical energydelivered to the tissue compressed between the jaw assemblies of thedevice based on the tissue thickness, density, and quality. If a tissuecompressed between the jaw assemblies is essentially homogeneous, theuser of the electrosurgical device may use simple controls to adjust theamount of electrical energy delivered to the tissue. However, it may berecognized that some tissues for hemostatic sealing are inhomogeneous inany one or more of their thickness, density, and/or quality. As aresult, a single control for the amount of electrical energy deliveredto the tissue compressed between the jaw assemblies may result in burnedportions as well as insufficiently sealed portions of the tissue. It istherefore desirable to have an electrosurgical device that may beconfigured to deliver a variety of electrical energies to a piece oftissue compressed between the jaw assemblies.

Electrosurgical instruments apply electrosurgical energy to seal tissue.However, the application of electrosurgical energy is not optimized forall tissue types. Some types of tissue require the application ofelectrosurgical energy in one form and other types of tissue require theapplication of electrosurgical energy in another form. Therefore, itwould be desirable, to treat different tissue types by applyingelectrosurgical energy in one form during a clamping procedure to cutand spread apart the tissue and after the clamping process, applyingelectrosurgical energy in another form to seal the tissue beforeadvancing a knife to sever the tissue. Therefore, the present disclosureprovides an electrosurgical cartridge that is configured to energizedifferent electrode configurations over different time periods tocombine or coordinate each of the different functions of the jaws of theend effector such as closing the jaws on tissue, applyingelectrosurgical energy to seal the tissue, and firing the cuttingelement to cut the tissue.

FIG. 57 is a cross-sectional view of a jaw member 5000 comprising anelectrosurgical cartridge such as, for example, a radio frequency (RF)cartridge 5002 supported by an elongated channel 5004, according to someaspects of the present disclosure. The RF cartridge 5002 may comprise anelongated slot 5014 extending through the RF cartridge 5002. The RFcartridge 5002 may comprise a first electrode 5006, 5008 and a secondelectrode 5010, 5012. The first electrode may comprise a first electrodesegment 5006 and a second electrode segment 5008 separated by theelongated slot 5014. The second electrode may comprise a third electrodesegment 5010 and a fourth electrode segment 5012 separated by theelongated slot 5014. The first and second electrode segments 5006, 5008may be closer to the lateral edges 5016, 5018 of the RF cartridge, andthe third and fourth electrode segments 5010, 5012 may be closer to theelongated slot 5014. The first and second electrodes may be arrangedsuch that when the jaw member 5000 is in a closed position with anotherjaw member, a distance between the first electrode 5006, 5008 and theother jaw member is larger than a distance between the second electrode5010, 5012 and the other jaw member. Further, central edges 5020, 5022of the first and second electrode segments 5006, 5008 may be closer tothe other jaw member than lateral edges 5024, 5026 of the first andsecond electrode segments 5006, 5008. For example, the first and secondelectrode segments 5006, 5008 may be at an angle α with the third andfourth electrode segments 5010, 5012. A width W1 of the first and secondelectrode segments 5006, 5008 may be larger than a width W2 of the thirdand fourth electrode segments 5010, 5012. As an example, the width W1 ofthe first and second electrode segments 5006, 5008 may be 0.060 inch,and the width W2 of the third and fourth electrode segments 5006, 5008may be 0.020 inch.

FIG. 58 is a diagram 5100 illustrating an operation of the firstelectrode, according to some aspects of the present disclosure. Thehorizontal axis represents time t, and the vertical axis represents aforce to close (“FTC”). An end effector comprising two jaws, one ofwhich being the jaw member 5000 for example, may be inserted into anorgan, for example liver, with the jaws open. Then the end effectorbegins clamping. For example, the jaw member 5000 shown in FIG. 57approaches another jaw member and applies a force on a tissuetherebetween. During the clamping, RF energy is supplied to the firstelectrode 5006, 5008, as indicated by the shaded region 5104. The RFenergy supplied to the first electrode 5006, 5008, for example, cut andspread apart parenchyma. As shown in FIG. 58, FTC 5102 increases in thebeginning, and then decreases gradually. The RF energy supplied to thefirst electrode 5006, 5008 may be stopped at a first time point t1,which may be determined as the time when the FTC 5102 falls below athreshold. The first time point t1 may also be determined as a timepoint when a proper tissue gap, for example 0.0005 inch to 0.1 inch, isformed.

FIG. 59 is a diagram 5200 illustrating an operation of the secondelectrode, according to some aspects of the present disclosure. Thehorizontal axis represents time t, and the vertical axis represents aforce to fire (“FTF”). As shown in FIG. 59, RF energy is switched to thesecond electrode 5010, 5012 after the first time t1, as indicated by theshaded area 5204. Although the two shaded areas 5104 and 5204 are shownas having the same height, the RF energy supplied to the first electrode5006, 5008 may be different from the RF energy supplied to the secondelectrode 5010, 5012. RF energy supplied to the second electrode 5010,5012, for example, seals one or more vessels. At a second time point t2after the first time point t1, a cutting member, for example a knife,may begin to advance or fire, as indicated by a FTF curve 5202. At athird time point t3 after the second time point t2. RF energy suppliedto the second electrode 5010, 5012, for example, may be stopped. In someaspects of the present disclosure, the beginning of RF energy suppliedto the second electrode 5010, 5012 may not immediately follow the end ofRF energy supplied to the first electrode 5006, 5008.

FIG. 60 is a logic flow diagram of a process 5300 depicting a controlprogram or a logic configuration for applying therapeuticelectrosurgical energy according to one aspect of this disclosure. Inone aspect, the electrosurgical energy is RF energy, for example. Thetherapeutic electrosurgical energy may be applied to prepare for cuttingand coagulating a surgical site such as, a liver, for example. Theelectrosurgical energy may be applied by lateral segmented electrodesfor use in tissue welding during closing or clamping (including displayfeedback of the tissue welding progress). A secondary energy switch maybe employed to allow automated application of the electrosurgical energyconcurrent with closure or clamping. A secondary set of electrodes witha thinner gap for vessel welding after parenchyma tissue welding alsomay be provided.

The process 5300 may be implemented with the surgical instrument 600shown in FIG. 18 and controlled by the control circuit 610. Accordingly,the control circuit 610 is configured to supply 5302 electrosurgicalenergy through the RF energy source 400 to the RF cartridge 609 of theend effector 602 in a first period of time as measured by thetimer/counter circuit 631. In one aspect, the RF cartridge 609 isremovably coupleable to an elongated channel of a first jaw of the endeffector 602 of the surgical instrument 600. The anvil 616 is thenclosed on the RF cartridge 609 apply 5304 a force to tissue locatedbetween the anvil 616 and the RF cartridge 609 during at least a part ofthe first time period as determined b the timer/counter circuit 631. Thecontrol circuit 610 then supplies 5306 electrosurgical energy to asecond electrode of the RF cartridge 609 of the end effector 602 in asecond period of time as determined by the timer/counter circuit 631after the end of the first period of time. The control circuit 610 isconfigured to operate the motor 608 to advance a knife such as theI-beam 614 through the tissue during at least a part of the second timeperiod.

Various aspects of the subject matter described herein are set out inthe following numbered examples:

EXAMPLE 1

An end effector for a surgical instrument, comprising: a first jaw; anda second jaw, wherein at least one of the first and second jaws isconfigured to move from a first position spaced apart from the other oneof the first and second jaws to a second position in which the spacebetween the first and second jaws is less than that of the firstposition, wherein the second jaw comprises: an elongated channel, and acartridge removably coupled to the elongated channel, comprising a firstelectrode configured to apply electrosurgical energy to a tissue and asecond electrode configured to apply electrosurgical energy to thetissue, wherein in the second position a distance between the firstelectrode and the first jaw is greater than a distance between thesecond electrode and the first jaw.

EXAMPLE 2

The end effector of Example 1, wherein the cartridge further comprises acentrally located elongated slot; the first electrode comprises a firstelectrode segment and a second electrode segment separated by theelongated slot; and the second electrode comprises a third electrodesegment and a fourth electrode segment separated by the elongated slot.

EXAMPLE 3

The end effector of Example 2, wherein a width of the first and secondelectrode segments is greater than a width of the third and fourthelectrode segments.

EXAMPLE 4

The end effector of one or more of Example 2 through Example 3, whereinthe third and fourth electrode segments are located between the firstelectrode segment and the second electrode segment.

EXAMPLE 5

The end effector of one or more of Example 2 through Example 4, whereinin the second position a distance between an central edge of the firstelectrode segment and the first jaw is smaller than a distance betweenan lateral edge of the first electrode segment and the first jaw; and adistance between an central edge of the second electrode segment and thefirst jaw is smaller than a distance between an lateral edge of thesecond electrode segment and the first jaw.

EXAMPLE 6

The end effector of one or more of Example 1 through Example 5, whereinthe first electrode is configured to apply electrosurgical energy to thetissue in a first time period; and the second electrode is configured toapply electrosurgical energy to the tissue in a second time period afterthe first time period.

EXAMPLE 7

The end effector of Example 6, wherein the first and second jaws areconfigured to apply a force to the tissue during at least a part of thefirst time period; and the end effector further comprises a knifeconfigured to advance to the tissue during at least a part of the secondtime period.

EXAMPLE 8

The end effector of Example 7, wherein the knife is configured to beginadvancing after the start of the second time period.

EXAMPLE 9

The end effector of one or more of Example 1 through Example 8, whereinthe electrosurgical energy radio frequency (RF) energy.

EXAMPLE 10

A cartridge for use in an end effector for a surgical instrument, thesurgical instrument comprising a first jaw and a second jaw, wherein atleast one of the first and second jaws is configured to move from afirst position spaced apart from the other one of the first and secondjaws to a second position in which the space between the first andsecond jaws is less than that of the first position, wherein thecartridge is configured to be removably coupled to an elongated channelof the second jaw, the cartridge comprising: a first electrodeconfigured to apply electrosurgical energy to a tissue; and a secondelectrode configured to apply electrosurgical energy to the tissue,wherein in the second position a distance between the first electrodeand the first jaw is greater than a distance between the secondelectrode and the first jaw.

EXAMPLE 11

The cartridge of Example 10, further comprising a centrally locatedelongated slot, wherein the first electrode comprises a first electrodesegment and a second electrode segment separated by the elongated slot;and the second electrode comprises a third electrode segment and afourth electrode segment separated by the elongated slot.

EXAMPLE 12

The cartridge of Example 11, wherein a width of the first and secondelectrode segments is greater than a second width of the third andfourth electrode segments.

EXAMPLE 13

The cartridge of one or more of Example 11 through Example 12, whereinthe third and fourth electrode segments are located between the firstelectrode segment and the second electrode segment.

EXAMPLE 14

The cartridge of one or more of Example 11 through Example 13, whereinin the second position a distance between an central edge of the firstelectrode segment and the first jaw is smaller than a distance betweenan lateral edge of the first electrode segment and the first jaw; and adistance between an central edge of the second electrode segment and thefirst jaw is smaller than a distance between an lateral edge of thesecond electrode segment and the first jaw.

EXAMPLE 15

The cartridge of one or more of Example 10 through Example 14, whereinthe first electrode is configured to apply electrosurgical energy to thetissue in a first time period; and the second electrode is configured toapply electrosurgical energy to the tissue in a second time period afterthe first time period.

EXAMPLE 16

The cartridge of one or more of Example 10 through Example 15, whereinthe electrosurgical energy radio frequency (RF) energy.

EXAMPLE 17

A method, comprising: supplying electrosurgical energy to a firstelectrode of a cartridge in a first period of time, wherein thecartridge is removably coupleable to an elongated channel of a first jawof an end effector of a surgical instrument; and supplyingelectrosurgical energy to a second electrode of the cartridge in asecond period of time after the first period of time.

EXAMPLE 18

The method of Example 17, further comprising: applying a force to atissue with the first jaw during at least a part of the first timeperiod; and advancing a knife to the tissue during at least a part ofthe second time period.

EXAMPLE 19

The method of Example 18, wherein advancing the knife begins after thestart of the second time period.

EXAMPLE 20

The method of one or more of Example 17 through Example 19, wherein theend effector further comprises a second jaw, the method furthercomprising moving at least one of the first and second jaws from a firstposition spaced apart from the other one of the first and second jaws toa second position in which the space between the first and second jawsis less than that of the first position and in the second position adistance between the first electrode and the second jaw is greater thana distance between the second electrode and the second jaw.

EXAMPLE 21

The method of one or more of Example 17 through Example 20, whereinsupplying electrosurgical energy comprises supplying radio frequency(RF) energy.

Electrosurgical Cartridge for Use in Thin Profile Surgical Cutting andStapling Instrument

In various open, endoscopic, and/or laparoscopic surgeries, for example,it may be desirable to coagulate, seal, and/or fuse tissue. One methodof sealing tissue relies upon the application of energy, such aselectrical energy, for example, to tissue captured or clamped within anend-effector or an end-effector assembly of a surgical instrument inorder to cause thermal effects within the tissue. Various mono-polar andbi-polar radio frequency (RF) surgical instruments and surgicaltechniques have been developed for such purposes. In general, thedelivery of RF energy to the captured tissue can elevate the temperatureof the tissue and, as a result, the energy can at least partiallydenature proteins within the tissue. Such proteins, such as collagen,for example, can be denatured into a proteinaceous amalgam thatintermixes and fuses, or seals, together as the proteins renature. Asthe treated region heals over time, this biological seal may bereabsorbed by the body's wound-healing process.

In certain arrangements of a bi-polar RF surgical instrument, thesurgical instrument can comprise opposing first and second jaws, whereineach jaw can comprise an electrode. In use, the tissue can be capturedbetween the jaws such that energy can flow between the electrodes in theopposing jaws and through the tissue positioned therebetween. Suchinstruments may have to seal many types of tissues, such as anatomicstructures having walls with irregular or thick fibrous content, bundlesof disparate anatomic structures, and/or substantially thick or thinanatomic structures.

Generally, when electrosurgical energy is applied, through electrodes,to a target tissue clamped in an electrosurgical end effector of asurgical device, heat provided to the target tissue in the target zone(e.g., near the electrodes) may be transferred laterally, damaging thetissue outside of the target zone and increasing the zone of coagulatedtissue laterally from the target zone. Excessive lateral spread of thecoagulation zone may be harmful to patients undergoing surgicalprocedures because more tissue is damaged and this may require morerecovery time. Moreover, the electrodes used to transmit theelectrosurgical energy may be typically placed on an electrically andthermally insulating material, and this may lead to overheating oftissue, which may cause more lateral thermal spread to the tissueoutside of the target zone and collateral tissue damage.

Aspects of the present disclosure may address the above noted problems.In an example aspect, an end effector may include a first jaw (e.g., acartridge and a channel) and a second jaw (e.g., anvil), a hot zone in acenter portion of the end effector, and cool zones in the side portionsof the end effector. The first jaw and the second jaw may define anelongate slot therebetween, and a cutting member is slideably receivablewithin the elongate slot to cut tissue located between the first jaw andthe second jaw. The first jaw may include electrically and thermallynonconductive insulative layers on each side of the centrally disposedelongate slot, and electrode layers configured to transmitelectrosurgical energy may be placed on the insulative layers in the hotzone. The first jaw also may include electrically insulating, thermallyconductive heat sink layers in the side portions of the first jaw in thecool zones. The heat sink layers may include tissue contacting surfacesthat may be in direct contact with the tissue when the tissue is clampedin the end effector. The heat sink layers may be configured to cool thetissue in the cool zones by transferring the heat in the tissue in thecool zones to the outside area to minimize the damage from the transferof heat from the target tissue in the hot zone to the tissue justoutside of the hot zone.

In an example aspect, the first jaw may include raised pads on each sideof the elongate slot under the electrode layers. The raised pads mayallow the electrode layers to be raised compared with the tissuecontacting surfaces of the heat sink layers so that more pressure, andultimately more heat, can be applied only to the target tissue moreprecisely while reducing the thermal spread to the lateral tissue. Theraised pads, in combination with the heat sink layers cooling the tissuejust outside of the target zone (e.g., hot zone) may lower thetemperature of the tissue just outside of the target zone significantlyand, thus, enable a physician to perform more precise sealing of tissuewithout excessive lateral thermal spread.

In an example aspect, the insulative layers may include an edge definedby a first surface facing the electrode layers and a second surfacefacing the elongate slot, and this edge may be chamfered to allow steamto escape through the elongate slot to prevent burning or overheating oftissue, preventing lateral thermal spread that may be caused by theexcessive heat from the overheating.

FIG. 61 shows a schematic cross-sectional view of an end effector 5500according to one aspect of this disclosure. The end effector 5500 mayinclude a first jaw 5505 and a second jaw 5610. In an example aspect,the first jaw 5505 may include an elongate channel 5530 (e.g., elongatechannel 1602) that is configured to operably support a cartridge (e.g.,a cartridge 5700) therein. In an example aspect, the first jaw 5505 andthe second jaw 5610 may define a slot therebetween. A cutting member(e.g., a blade or a knife member 1330) may be slideably receivablewithin the slot to cut tissue clamped within the end effector 5500. Theslot in the first jaw 5505 is an elongate slot 5560 (e.g., elongate slot1712). The elongate slot 5560 may extend from a proximate end of thefirst jaw 5505. The slot in the second jaw 5610 is an anvil slot 5630(e.g., anvil slot 1815). In an example, the slots 5560, 5630 may bedisposed in the center of the first and second jaws 5505, 5610. Inanother example, the slots 5560, 5630 may be disposed in any othersuitable places in the first and second jaws 5505, 5610.

In an example aspect, the first jaw 5505 may include a first insulativelayer 5510L and a second insulative layer 5510R. The first insulativelayer 5510L may be on the left side of the elongate slot 5560 and thesecond insulative layer 5510R may be on the right side of the elongateslot 5560. In the illustrated example, the first insulative layer 5510L,the second insulative layer, and the elongate slot 5560 are disposed ina center portion of the first jaw 5505. In an example aspect, the centerportion of the jaws 5505, 5610 may cover around ⅓-½ of the entireportions of the jaws 5505, 5610 and be located in the center thereof. Inan example aspect, the first insulative layer 5510L and the secondinsulative layer 5510R may comprise a thermally and electricallynon-conductive material such as a molded plastic.

In an example aspect, the first jaw 5505 also may include a firstelectrode layer 5540L on the first insulative layer 5510L and a secondelectrode layer 5540R on the second insulative layer 5510R. The firstelectrode layer 5540L and the second electrode layer 5540R may beconfigured for direct application of electrosurgical energy (e.g., RFenergy) to the tissue (T) to form a hemostatic (coagulation orcauterization) line on the tissue adjacent the electrode layers 5540L,5540R along the elongate slot 5560. The first electrode layer 5540L andthe second electrode layer 5540R may be located in the center portion ofthe first jaw 5505. In an example aspect, the first electrode layer5540L and the second electrode layer 5540R may include a direct contactmetal electrode. In an example aspect, each of the first electrode layer5540L and the second electrode layer 5540R may further include a flexcircuit. In this case, the direct contact metal electrode may bedeposited on the flex circuit. In an example aspect, the first electrodelayer 5540L and the second electrode layer 5540R may define a hot zone5650 near the first and second electrode layers 5540L, 5540R. Asillustrated in FIG. 61, the hot zone 5650 may be in the center portionof the end effector 5500 (and the first and second jaws 5505, 5610).

In an example aspect, the first jaw 5505 may include a first heat sinklayer 5520L in a left side portion of the first jaw 5505 and a secondheat sink layer 5520R in a right side portion of the first jaw 5505. Thefirst heat sink layer 5520L may include a first tissue contactingsurface 5525L, and the second heat sink layer 5520R may include a secondtissue contacting surface 5525R. The tissue contacting surfaces 5525L,5525R may be in direct contact with the tissue (T) when the tissue (T)is clamped in the end effector 5500. In an example aspect, the firstheat sink layer 5520L may define a first cool zone 5660 in the left sideportion of the end effector 5500 (or the first jaw 5505) and the secondheat sink layer 5520R may define a second cool zone 5670 in the rightside portion of the end effector 5500 (or the first jaw 5505). The firstheat sink layer 5520L and the second heat sink layer 5520R may beconfigured to cool the tissue (T) in the first and second cool zones5560, 5570 to minimize the transfer of heat from the tissue in the hotzone 5650 to the tissue outside of the hot zone 5560, preventing damagesto the tissue just outside of the hot zone 5560 (and ultimately justoutside of the end effector 5500). In an example aspect, the first andsecond heat sink layers 5520L, 5520R may be made of an electricallyinsulating, thermally conductive material, such as a ceramic material(e.g., aluminum nitride) to dissipate heat from the tissue adjacent theheat sink layers 5520L, 5520R.

In an example aspect, the first and second insulative layers 5510L,5510R may be around 0.01-0.10 inches away from a center line C of theend effector 5500. In an example aspect, the horizontal distance 5555between the electrode layer 5540L/5540R and the center line C may be inthe range of about 0.01 inches to 0.10 inches. In an example aspect, thefirst and second heat sink layers 5520L, 5520R may be around 0.03-0.20inches away from the center line C.

In an example aspect, the first electrode layers 5540L and the firstheat sink layers 5520L may define a first horizontal distance 5545Lbetween the first electrode layers 5540L and the first heat sink layers5520L. Similarly, the second electrode layers 5540R and the second heatsink layers 5520R may define a second horizontal distance 5545R betweenthe second electrode layers 5540R and the second heat sink layers 5520R.The first and second horizontal distances 5545L, 5545R may be very smallto provide a precise tissue sealing for a thin profile end effector withno or little lateral thermal spread. In an example aspect, the first andsecond horizontal distances 5545L, 5545R may be in the range of 0.00 toabout 0.50 inches, preferably in the range of about 0.00 to 0.10 inches,more preferably in the range of 0.00 to about 0.03 inches. In an exampleaspect, the first and second horizontal distances 5545L, 5545R may beless than half of the width of the electrode layers 5540L, 5540R. Inanother example aspect, the first and second horizontal distances 5545L,5545R may have any other suitable length.

In an example aspect, the first jaw 5505 may include a feature that isconfigured to apply a pressure to the tissue by the first electrodelayer 5540L and the second electrode layer 5540R in the hot zone 5650that is greater than a pressure applied to the tissue (T) by the tissuecontacting surfaces 5525L, 5525R of the first and second heat sinklayers 5520L, 5520R. In an example aspect, this feature may comprise afirst raised pad 5550L and a second raised pad 5550R. The first raisedpad 5550L and the second raised pad 5550R may allow the first electrodelayer 5540L and the second electrode layer 5540R to be raised comparedwith the tissue contacting surfaces 5525L, 5525R so that more pressure,and ultimately more heat, can be applied only to a target tissue (e.g.,tissue in the hot zone 5650 adjacent the electrode layers 5540L, 5540R)more precisely with less lateral thermal spread.

Generally, the thickness of typical electrodes itself may be too thin toprovide a meaningful pressure to compress the target tissue so that theenergy and heat can be centered in the target tissue with less lateralthermal spread. In an example aspect, the raised pads 5550L, 5550R maynot include the electrode layers 5540L, 5540R. The raised pads 5550L,5550R may comprise the insulative layers 5510L, 5510R, or a combinationof the insulative layers 5510L, 5510R and the heat sink layers 5520L,5520R. In another example aspect, the raised pads 5550L, 5550R also mayinclude the electrode layers 5540L, 5540R in addition to the insulativelayers 5510L, 5510R and/or the heat sink layers 5520L, 5520R. In anexample aspect, the thickness of the raised pads 5550L, 5550R (e.g., thevertical distance between the electrode layers 5540L, 5540R and thetissue contacting surfaces 5525L, 5525R) may be at least three to fivetimes of the thickness of the electrode layers 5540L, 5540R. In anexample aspect, the thickness of the raised pads 5550L, 5550R may be inthe range of about 0.05.inches to 0.10 inches. In another exampleaspect, the raised pads 5550L, 5550R may have any suitable thicknessthat is sufficient to reduce the lateral thermal spread.

In an example aspect, the first insulative layer 5510L may include afirst surface 5512L facing the first electrode layer 5540L and a secondsurface 5514L facing the elongate slot 5560. The first surface 5512L andthe second surface 5514L of the first insulative layer 5510L may definea first edge 5570L. Similarly, the second insulative layer 5510R mayinclude a first surface 5512R facing the first electrode layer 5540R anda second surface 5514R facing the elongate slot 5560. The first surface5512R and the second surface 5514R of the second insulative layer 5510Rmay define a second edge 5570R. In an example aspect, the first andsecond edges 55740L, 5570R may be chamfered to allow steam to escapethrough the elongate slot 5560 to prevent burning or overheating oftissue that can lead to collateral tissue damage.

The elongate channel 5530 may be formed under the insulative layers5510L, 551OR and heat sink layers 5520L, 5520R. In an example aspect,the elongate channel 5530 may comprise a thermally conductive metallicmaterial and in direct contact with the first and second heat sinklayers 5520L, 5520R to facilitate the cooling of the tissue in the firstand second cool zones 5660, 5670. For example, the heat in the heat sinklayers 5520L, 5520R transferred from the tissue may be furthertransferred to the metallic channel 5530 and this may help reduce thetissue temperature in the cool zones 5660, 5670 more quickly.

In an example aspect, during coagulating or cutting, the averagetemperature of tissue in the cool zones 5660, 5670 may be much lowerthan the average temperature of tissue in the hot zone 5650. After thecoagulating or cutting, the temperature of tissue in the cool zones5660, 5670 may decrease more quickly than the temperature of tissue inthe hot zone 5650.

In an example aspect, the second jaw 5610 may comprise an anvil that ispivotally supported relative to the elongate channel 5530. The secondjaw 5610 may be selectively moved toward and away from a surgicalcartridge supported in the elongate channel 5630 between open and closedpositions by actuating a closure drive system (e.g., closure drivesystem 510). In FIG. 61, the end effector 5500 is in a closed positionwith tissue (T) clamped between the first jaw 5505 and the second jaw5610. The anvil slot 5630 may open into an upper opening 5640 that iswider than the anvil slot 5630 as shown in FIG. 61. The upper openingmay extend longitudinally through the second jaw 5610, for example, toaccommodate the anvil engagement features (e.g., anvil engagementfeature 1336) on the cutting member (e.g., knife member 1330) duringfiring. The second jaw 5610 also may include fastener forming pockets5620 (e.g., fastener forming pockets 1814) formed therein on each sideof the anvil slot 5630.

FIG. 62 shows a perspective view of the end effector 5500 according toone aspect of this disclosure. In FIG. 62, the end effector 5500 is inan open position. The second jaw 5610 may be moveable relative to thefirst jaw 5505. The first jaw 5505 may include a cartridge 5700 that issized and shaped to be removably received and supported in the elongatechannel 5530. In an example aspect, the cartridge 5700 may include theinsulative layers 5510L, 5510R, the heat sink layers 5520L, 5520R, andthe electrode layers 5540L, 5540R. In an example aspect, a distal end ofthe first electrode layer 5540L may be connected to a distal end of thesecond electrode layer 5540R as shown in FIG. 62, and the elongate slot5560 may extend through the center of the electrodes 5540L, 5540R. Inanother example aspect, the first electrode layer 5540L may be separatefrom the second electrode layer 5540R. The first tissue contactingsurface 5525L of the first heat sink layer 5520L may be disposed on theleft side of the first electrode layer 5540L, and the second tissuecontacting surface 5525R of the second heat sink layer 5520R may bedisposed on the right side of the second electrode layer 5540R.

The first jaw 5505 may include a microchip 5710 in the distal portion ofthe first jaw 5505. The microchip 5710 may be configured to control theelectrode layers 5540L, 5540R (e.g., providing electrosurgical energy).The microchip 5710 may be connected to a flexible cartridge circuit 5720(e.g., flexible cartridge circuit 1750), which may in turn connected toa channel circuit (e.g., channel circuit 1670). The first jaw 5505 alsomay include a dissector electrode 5730 at a distal end 5740. Thedissector electrode 5730 may be connected to a source of electricalenergy (e.g., RF generator 400) and configured to transmitelectrosurgical energy (RF energy) to the tissue for dissecting thetissue and/or coagulating blood. The dissector electrode 5730 may beisolated from and operated separately from the electrode layers 5540L,5540R.

Various aspects of the subject matter described herein are set out inthe following numbered examples:

EXAMPLE 1

An surgical instrument comprising: an end effector comprising: a firstjaw; a second jaw that is movable relative to the first jaw; a hot zonein a center portion of the end effector; a first cool zone in a leftside portion of the end effector; and a second cool zone in a right sideportion of the end effector; and an elongate slot defined between thefirst jaw and the second jaw, the elongate slot configured to slideablyreceive a cutting member within the elongate slot to cut tissue locatedbetween the first jaw and the second jaw, wherein the elongate slot islocated in the center portion of the end effector; wherein the first jawcomprises: a first insulative layer in the hot zone, wherein the firstinsulative layer is on the left side of the elongate slot; a secondinsulative layer in the hot zone, wherein the second insulative layer ison the right side of the elongate slot; a first electrode layer on thefirst insulative layer; a second electrode layer on the secondinsulative layer, wherein the first electrode layer and the secondelectrode layer are configured for direct application of electrosurgicalenergy to the tissue in the hot zone; a first heat sink layer in thefirst cool zone; and a second heat sink layer in the second cool zone,wherein the first heat sink layer and the second heat sink layer areconfigured to cool the tissue in the first and second cool zones tominimize lateral thermal spread.

EXAMPLE 2

The surgical instrument of Example 1, wherein each of the first andsecond heat sink layers comprises a thermally conductive ceramicmaterial.

EXAMPLE 3

The surgical instrument of one or more Example 1 through Example 2,wherein each of the first electrode layer and the second electrode layercomprises a direct contact metal electrode.

EXAMPLE 4

The surgical instrument of Example 3, wherein each of the firstelectrode layer and the second electrode layer further comprises a flexcircuit wherein the direct contact metal electrode is deposited on theflex circuit.

EXAMPLE 5

The surgical instrument of one or more Example 1 through Example 4,wherein each of the first heat sink layer and the second heat sink layercomprises a tissue contacting surface.

EXAMPLE 6

The surgical instrument of Example 5, wherein each of the firstelectrode layer and the second electrode layer are raised compared withthe tissue contacting surfaces of the first heat sink layer and thesecond heat sink layer, which allows the end effector to apply apressure to the tissue by the first electrode layer and the secondelectrode layer in the hot zone that is greater than a pressure appliedto the tissue by the tissue contacting surfaces of the first heat sinklayer and the second heat sink layer.

EXAMPLE 7

The surgical instrument of one or more Example 1 through Example 6,wherein the first insulative layer and the second insulative layercomprise a thermally and electrically non-conductive material.

EXAMPLE 8

The surgical instrument of one or more Example 1 through Example 7,wherein the first insulative layer comprises a first surface facing thefirst electrode layer and a second surface facing the elongate slot,wherein the first surface and the second surface define a first edge,wherein the first edge is chamfered to allow steam to escape.

EXAMPLE 9

The surgical instrument of Example 8, wherein the second insulativelayer comprises a third surface facing the second electrode layer and afourth surface facing the elongate slot, wherein the third surface andthe fourth surface define a second edge, wherein the second edge ischamfered to allow the steam to escape.

EXAMPLE 10

The surgical instrument of one or more Example 1 through Example 9,wherein the first jaw further comprises a channel under the first andsecond heat sink layers.

EXAMPLE 11

The surgical instrument of Example 10, wherein the channel comprises athermally conductive metallic material, and the channel is in directcontact with the first and second heat sink layers to facilitate thecooling of the tissue in the first and second cool zones.

EXAMPLE 12

An surgical instrument comprising: an end effector comprising: a firstjaw; a second jaw that is movable relative to the first jaw; a hot zonein a center portion of the end effector; a first cool zone in a leftside portion of the end effector; a second cool zone in a right sideportion of the end effector; and a dissector tip at a distal end of theend effector; and an elongate slot defined between the first jaw and thesecond jaw, the elongate slot configured to slideably receive a bladewithin the elongate slot to cut tissue located between the first jaw andthe second jaw, wherein the elongate slot is located in the centerportion of the end effector; wherein the first jaw comprises: a firstinsulative layer in the hot zone, wherein the first insulative layer ison the left side of the elongate slot; a second insulative layer in thehot zone, wherein the second insulative layer is on the right side ofthe elongate slot; a first electrode layer on the first insulativelayer; a second electrode layer on the second insulative layer, whereinthe first electrode layer and the second electrode layer are configuredfor direct application of electrosurgical energy to the tissue in thehot zone, wherein each of the first electrode layer and the secondelectrode layer comprises a direct contact metal electrode; a first heatsink layer in the first cool zone; and a second heat sink layer in thesecond cool zone, wherein the first heat sink layer and the second heatsink layer are configured to cool the tissue in the first and secondcool zones to minimize lateral thermal spread.

EXAMPLE 13

The surgical instrument of Example 12, wherein each of the first andsecond heat sink layers comprises a thermally conductive ceramicmaterial.

EXAMPLE 14

The surgical instrument of one or more Example 12 through Example 12,wherein each of the first electrode layer and the second electrode layerfurther comprises a flex circuit wherein the direct contact metalelectrode is deposited on the flex circuit.

EXAMPLE 15

The surgical instrument of one or more Example 12 through Example 14,wherein each of the first heat sink layer and the second heat sink layercomprises a tissue contacting surface.

EXAMPLE 16

The surgical instrument of Example 15, wherein each of the firstelectrode layer and the second electrode layer are raised compared withthe tissue contacting surfaces of the first heat sink layer and thesecond heat sink layer, which allows the end effector to apply apressure to the tissue by the first electrode layer and the secondelectrode layer in the hot zone that is greater than a pressure appliedto the tissue by the tissue contacting surfaces of the first heat sinklayer and the second heat sink layer.

EXAMPLE 17

The surgical instrument of one or more Example 12 through Example 16,wherein the first insulative layer and the second insulative layercomprise a thermally and electrically non-conductive material.

EXAMPLE 18

The surgical instrument of one or more Example 12 through Example 17,wherein the first insulative layer comprises a first surface facing thefirst electrode layer and a second surface facing the elongate slot,wherein the first surface and the second surface define a first edge,wherein the first edge is chamfered to allow steam to escape.

EXAMPLE 19

The surgical instrument of one or more Example 12 through Example 18,wherein the first jaw further comprises a channel under the first andsecond heat sink layers.

EXAMPLE 20

The surgical instrument of Example 19, wherein the channel comprises athermally conductive metallic material, and the channel is in directcontact with the first and second heat sink layers to facilitate thecooling of the tissue in the first and second cool zones.

Surgical End Effector to Adjust Jaw Compression

In an electrosurgical instrument the density of tissue located betweenthe jaws of an end effector varies along the length of the end effector.High density tissue may be located in a proximal portion of the endeffector, medium density tissue may be located at a mid portion of theend effector and the low density tissue may be located at a distalportion of the end effector. A compliant jaw may be employed to applyvariable compression on the variable density tissue. A constant energydensity may not be effective to seal the variable density tissue alongthe length of a compliant jaw for applying variable compression.Therefore, the present disclosure provides an electrosurgical cartridgethat is configured to deliver variable energy density along the lengthof the compliant jaw for variable compression to provide a suitable sealof the variable density tissue.

As disclosed above, with respect to FIGS. 10-12, an electrosurgicaldevice may include an end effector 1500 that includes a removableelectrosurgical cartridge, such as, for example, a radio frequency (RF)surgical cartridge 1700 disposed within an elongate channel 1602 of afirst jaw assembly 1600. In some aspects, the electrosurgical device maybe electrically connected to an RF generator designed to supply RFenergy to the RF surgical cartridge and to its components. FIG. 10particularly depicts an aspect of the RF surgical cartridge 1700 havinga cartridge body 1712 formed with a centrally disposed raised electrodepad 1720. As can be most particularly seen in FIG. 6, the elongate slot1712 extends through the center of the electrode pad 1720 and serves todivide the pad 1720 into a left pad segment 1720L and a right padsegment 1720R. Returning to FIG. 10, a right flexible circuit assembly1730R is attached to the right pad segment 1720R and a left flexiblecircuit assembly 1730L is attached to the left pad segment 1720L. Inaddition, the right flexible circuit assembly 1730R includes a “phaseone”, proximal right electrode 1736R and a “phase two” distal rightelectrode 1738R. Further, the left flexible circuit assembly 1730Lincludes a “phase one”, proximal left electrode 1736L and a “phase two”distal left electrode 1738L.

FIGS. 63A and 63B depict an alternative aspect of an end effector 1500having a replaceable electrosurgical cartridge, such as, for example, anRF surgical cartridge 1700. FIG. 63A depicts the end effector 1500 in anopen configuration and FIG. 63B depicts the end effector 1500 in aclosed configuration. In the closed configuration, a first jaw assembly1600 and a second jaw assembly 1800 of the end effector 1500 may bespaced proximate to each other at a distance that may result in a pieceof tissue 6070 placed therebetween being subjected to a clampingpressure. In the open configuration, the first jaw assembly 1600 and thesecond jaw assembly may be spaced at a greater distance. The open orclosed configuration of the end effector 1500 may be determined by theposition and operative action of a proximal closure tube 1910.

As depicted in FIG. 63A, the end effector 1500 includes a first jawassembly 1600 that may include an elongate channel to receive thereplaceable RF surgical cartridge 1700. The RF surgical cartridge 1700includes a cartridge body 1710 on which one or more electrodes may bedisposed. In the aspect depicted in FIG. 63A, the RF surgical cartridge1700 may include two types of electrodes, including one or more shearelectrodes 6038 and a dissector electrode 6238. The one or more shearelectrodes 6038 may generally have an elongated aspect that may extendalong a longitudinal axis of the RF surgical cartridge 1700. In somenon-limiting aspects, one of a pair of shear electrodes 6038 may bedisposed on either side of the elongate slot. The dissector electrode6238 may be disposed at a distal end of the cartridge body 1710. Furtherfeatures of the RF surgical cartridge 1700 may include a jaw spacer 6060at the distal end of the cartridge body 1710. The jaw spacer may act toprevent an inner surface of the anvil 1810 from contacting any one ormore of the shear electrodes 6038 and the dissector electrode 6238, asdepicted in FIG. 63B.

The one or more shear electrodes 6038 in addition to the dissectorelectrode 6238 may be disposed on the flexible circuit assembly that maybe part of a flexible cartridge circuit 1750. The one or more shearelectrodes 6038 may operate to deliver any amount of RF energy to atissue 6070 disposed proximate to the one or more shear electrodes 6038.FIG. 63B, for example, depicts a piece of tissue 6070 clamped betweenthe first jaw assembly 1600 and the second jaw assembly 1800 accordingto clamping motion CM. In some aspects, a combination of RF energydelivered to the tissue 6070 proximate to the shear electrodes 6038 andthe compressive force generated by the first jaw assembly 1600 and thesecond jaw assembly 1800 due to the clamping motion CM, may result inthe generation of a hemostatic seal in the tissue. The dissectorelectrode 6238 may be used to specifically spot treat tissue by theapplication of RF energy. Each of the one or more shear electrodes 6038and the dissector electrode 6238 may be electrically coupled to the RFenergy generator.

Each of the one or more shear electrodes 6038 may further include one ormore electrode portions. For example, as depicted in FIG. 10, each ofthe right and left shear electrodes may include a separate proximalelectrode and a distal electrode (1736R, 1738R, and 1736L, 1738L,respectively). For each of the right and left shear electrodes, each ofthe proximal electrodes and distal electrodes may be disposed along orparallel to a longitudinal axis of the RF cartridge. The proximalelectrodes (1736R,L) may be separately activated during a “phase one”procedure and the distal electrodes (1738R,L) may be separatelyactivated during a “phase two” procedure. In the aspect depicted in FIG.63A, each of the shear electrodes 6038 may be functionally separatedinto multiple functional electrode portions, 6138 a-c. Similar to theaspect depicted in FIG. 10, the electrode portions 6138 a-c may bedisposed along or parallel to a longitudinal axis of the RF cartridge.Each electrode portion 6138 a-c may deliver an amount of RF energy to atissue proximate thereto, but an amount of RF energy delivered by anyone electrode portion may differ from an amount of RF energy deliveredby a different electrode portion. In one non-limiting example, an amountof RF energy delivered to a tissue proximate to a low-energy electrodeportion 6138 a may be less than an amount of RF energy delivered to atissue proximate to a mid-energy electrode portion 6138 b. Similarly, anamount of RF energy delivered to a tissue proximate to the mid-energyelectrode portion 6138 b may be less than an amount of RF energydelivered to a tissue proximate to the high-energy electrode portion6138 c. In some aspects, each of the electrode portions 6138 a-c may beseparately actuatable by means of any appropriate RF electricalswitching component. In some alternative aspects, all or some number ofthe electrode portions 6138 a-c may be actuated together.

As noted above, the effectiveness of a hemostatic seal of a tissue maybe dependent on both a compressive pressure applied to the tissue aswell as an amount of RF energy delivered to the compressed tissue. Theamount of RF energy delivered to the tissue should be sufficient to forman effective hemostatic seal. If too little RF energy is delivered tothe tissue, the hemostatic seal may not properly form. Alternatively, iftoo much RF energy is delivered to the tissue, the tissue may be charredor damaged and be unable to form the hemostatic seal. The amount of RFenergy necessary to form the effective hemostatic seal may depend oncharacteristics of the tissue including, without limitation, a tissuethickness, a tissue density, and a tissue composition. In some examples,a piece of tissue to receive a hemostatic seal may be effectivelyhomogeneous with respect to the tissue thickness, the tissue density,and/or the tissue composition. Alternatively, a piece of tissue toreceive a hemostatic seal may be heterogeneous with respect to thetissue thickness, the tissue density, and/or the tissue composition.

An electrosurgical device having shear electrodes composed of a varietyof electrode portions may be used to form an effective hemostatic sealacross such a heterogeneous tissue. In the aspect of the end effector1500 depicted in FIG. 63B, the tissue 6070 may be heterogeneous and havetissue sections that may differ in any one or more of the tissuethickness, the tissue density, and/or the tissue composition. In anon-limiting example, the tissue 6070 may have a high-densitycomposition 6170 a, a mid-density composition 6170 b, and a low-densitycomposition 6170 c. A comparison of FIG. 63A with FIG. 63B illustratesthat an effective hemostatic seal of a tissue having a high-densitycomposition 6170 a may be made using a low energy electrode portion 6138a. Similarly, an effective hemostatic seal of a tissue having amid-density composition 6170 b may be made using a mid-energy electrodeportion 6138 b and an effective hemostatic seal of a tissue having alow-density composition 6170 c may be made using a high-energy electrodeportion 6138 c.

The amount of RF energy delivered by an electrode may depend, at leastin part, on the RF energy density at the electrode surface. Thus, avariation in one or more of the electrode surface properties may be usedto adjust the RF energy delivered by the electrode at that portion ofthe surface. In one aspect, the resistivity of the electrode surfacematerial may be adjusted to control the RF energy delivered at thatelectrode surface. In another aspect, the dimensions of the electrodesurface (for example, electrode width) may be adjusted to control the RFenergy delivered at that electrode surface. In another aspect, theelectrode surface may incorporate physical features that may permitcontrol of the RF energy delivered at that electrode surface. Examplesof such features may include the inclusion of resistive or electricallyinsulative components on or within the electrode surface.

FIG. 64 depicts some example shear electrodes 6038 a-d that mayincorporate any number or type of features 6139 a-d. Each of the shearelectrodes 6038 a-d may comprise a shear electrode surface 6039 a-dwhich may be composed of an electrically conductive material, especiallyone designed to conduct RF energy. The disposition of the features 6139a-d on the shear electrode surface may encompass one or more patternedenergy delivery surfaces. Thus, one aspect of a shear electrode 6038 amay have a shear electrode surface 6039 a having a patterned energydelivery surface incorporating a set of transverse rectilinear features6139 a. Another aspect of a shear electrode 6038 b may have a shearelectrode surface 6039 b having a patterned energy delivery surfaceincorporating a set of circular features 6139 b. Yet another aspect of ashear electrode 6038 c may have a shear electrode surface 6039 c havinga patterned energy delivery surface incorporating a set of concavequadrilateral (“chevron-shaped”) features 6139 c. While the features,such as 6139 a-c may be formed from discrete geometrical shapes, thefeatures may also comprise complex components resulting in a graduatedfeature 6139 d which may continuously or almost-continuously span aportion or portions of the surface of the shear electrode surface 6039d.

It may be recognized that an amount of RF energy that may be deliveredby a portion of a shear electrode 6038 to a tissue may be controlled bya number, type, size, and/or area density of the features 6139 a-dforming a particular aspect of a patterned energy delivery surface. FIG.64, for example, depicts that a low-energy portion 6138 a of a shearelectrode may have a patterned energy delivery surface incorporating alarger number of features (for example 6139 a-d) than a mid-energyportion 6138 b of a shear electrode. Similarly, a mid-energy portion6138 b of a shear electrode may have a patterned energy delivery surfaceincorporating a larger number of features (for example 6139 a-d) than ahigh-energy portion 6138 c of a shear electrode.

Although three energy portions 6138 a-c are depicted in FIGS. 63A and64, it may be recognized that a shear electrode 6038 may have any numberof discrete energy portions. Each of the discrete energy portion may becomposed of a patterned energy delivery surface. Non-limiting examplesof the number of energy portions incorporated into a shear electrode6038 may include two energy portions, three energy portions, four energyportions, five energy portions, or any finite number of energy portions.Further, as disclosed above with respect to example shear electrode 6038d, the surface of the shear electrode 6038 d may have a patterned energydelivery surface incorporating a graduated feature 6039 d configured tosupply a continuum of RF energies across the surface of the shearelectrode 6038 d. The continuum of RF energies supplied by the graduatedfeature 6039 d may include, without limitation, a linear continuum of RFenergies across the surface of the shear electrode 6038 d, a quadraticcontinuum of RF energies, a logarithmic continuum of RF energies acrossthe surface of the shear electrode 6038 d, or an exponential continuumof RF energies across the surface of the shear electrode 6038 d.

It should be recognized that the individual features 6139 a-d asdepicted in FIG. 64 are non-limiting examples of features 6139 a-d thatmay be incorporated on a shear electrode surface 6039 a-d. Othernon-limiting example of such features may include features that arelinear, circular, elliptical, oval, rectangular, square, roundedrectangular, or have a geometry defined by any closed two-dimensionalshape. For any aspect of a shear electrode 6038, all of the features mayhave the same shape or may have differing shapes. For any aspect of ashear electrode 6038, all of the features may have the same size or mayhave differing sizes. For any aspect of a shear electrode 6038, all ofthe features may be physically isolated from each other, may becontiguous to each other, or may be a combination of physically isolatedand continuous with respect to each other.

As further disclosed above, each of the energy portions may include apatterned energy delivery surface. Each patterned energy deliverysurface may incorporate any number, size, shape, or area density offeatures. Each patterned energy delivery surface of a particular aspectof a shear electrode may have features having identical shapes althoughthe features may differ in number, size, and/or area density between anytwo patterned energy delivery surfaces of the electrode. Each patternedenergy delivery surface of a particular aspect of a shear electrode mayhave an identical number of features although the features may differ inshape, size, and/or area density between any two patterned energydelivery surfaces of the electrode. Each patterned energy deliverysurface of a particular aspect of a shear electrode may have featureshaving identical sizes although the features may differ in number,shape, and/or area density between any two patterned energy deliverysurfaces of the electrode. Each patterned energy delivery surface of aparticular aspect of a shear electrode may have features havingidentical feature area density on the shear electrode surface althoughthe features may differ in number, size, and/or shape between any twopatterned energy delivery surfaces of the electrode.

As disclosed above, the features 6139 a-d may be formed from anelectrically insulative material deposited on or in a shear electrode6038. In one non-limiting aspect, the features 6139 a-d depicted in FIG.64 may be fabricated by removing portions from the shear electrodesurface 6039 a-d to form recessed features, for example by the use of anend-mill, and then using a fabrication method to deposit theelectrically insulative material in the recessed features to form thefeatures. Alternative methods of fabricating the features 6139 a-d mayinclude, for example, molding the electrode to include the recessedfeatures before depositing the electrically insulative materialtherewithin. The one or more recessed features may extend partiallythrough a thickness of the shear electrode 6038 a-d.

Alternatively, the one or more recessed features may extend completelythrough the thickness of the shear electrode 6038 a-d, thereby allowingthe recessed feature to receive the electrically insulative materialeither from a top side or a bottom side of the electrode. Theelectrically insulative material may completely fill the recessedfeatures, thereby forming a surface co-planar with the shear electrodesurface 6039 a-d. In an alternative aspect, the electrically insulativematerial may incompletely fill the recessed features, thereby forming asurface recessed from the shear electrode surface 6039 a-d. In yet anadditional aspect, the electrically insulative material may overfill therecessed features, thereby forming a surface protruding above the shearelectrode surface 6039 a-d.

In anther non-limiting aspect, the features 6139 a-d depicted in FIG. 64may be fabricated by a deposition method. In one non-limiting example,the shear electrode surface 6039 a-d may be coated with an electricallyinsulative material from which portions have been removed, therebyuncovering the electrode surface therebelow. The features 6139 a-d maybe fabricated by removing portions of the deposited electricallyinsulative material, for example by first contacting the electricallyinsulative material with the shear electrode surface 6039 a-d and thenusing a fabrication method to remove the portions of the material toform the features 6139 a-d. Alternative deposition methods offabricating the features 6139 a-d may include, for example, printing thefeatures 6139 a-d directly on the shear electrode surface 6039 a-d.Additional alternative methods for producing the features 6139 a-d onthe shear electrode surface 6039 a-d may also be employed.

Disclosed above are aspects of an RF electrode that may be a componentof a removable RF cartridge for use with an electrosurgical system. Suchan RF electrode may incorporate one or more features incorporated intoone or more patterned energy delivery surfaces designed to modify anamount of RF energy that may be sourced by a surface or one or moresurface portions of the electrode to a tissue placed proximate thereto.Although a plurality of aspects of such features and/or patterned energydelivery surfaces has been disclosed herein, such aspects are not to beconstrued as limiting. Thus, the patterned energy delivery surfaces mayinclude any appropriate features that may be configured on a surface ofone or more jaw assemblies or electrodes of an electrosurgical system.The patterned energy delivery surfaces may generally include featuresapplied to a planar surface of an electrode, to one or more raised orelevated features that extend vertically above a surface of anelectrode, or to one or more depressed features that extend verticallybelow a surface of an electrode. It may be understood that the term“electrically insulative material disposed on an electrode” encompassesthe application of the material on a planar surface of an electrode, toone or more raised or elevated features that extend vertically above asurface of an electrode, or to one or more depressed features thatextend vertically below a surface of an electrode. No limitations,expressed or implied, are herein imposed on methods of fabricating thefeatures.

The patterned energy delivery surfaces may encompass a single feature ormultiple features. The single feature or multiple features may have alimited extent, such as a small circular portion of the electricallyinsulative material disposed on an electrode. The single feature ormultiple features may have a more extended extent such as an elongatedportion of the electrically insulative material disposed on anelectrode. The single feature or multiple features—either of limitedextent or of extended extent—are not limited in their respective shapes,sizes, or dimensions on an electrode surface. The single feature ormultiple features—either of limited extent or of extended extent—are notlimited in their respective dispositions about the surface of theelectrode. Thus, as an example, an elongated portion of the electricallyinsulative material may extend along an axis essentially parallel to alongitudinal axis of the electrode. Alternatively, an elongated portionof the electrically insulative material may extend along an axisessentially perpendicular to a longitudinal axis of the electrode. Inyet another alternative example, an elongated portion of theelectrically insulative material may extend along an axis neitheressentially parallel to nor essentially perpendicular to a longitudinalaxis of the first electrode.

The patterned energy delivery surfaces may incorporate multiple featuresthat may include any combination or combinations of portions of theelectrically insulative material disposed on an electrode surface orportions removed from a coating of an electrically insulative materialdisposed on the electrode surface. Multiple features may be combined.Further, multiple features may be symmetrically disposed about thesurface of the electrode or they may be asymmetrically disposed aboutthe surface of the electrode. Multiple features—either of limited extentor of extended extent—are not limited in their dispositions about thesurface of the electrode with respect to each other. contemplated. It isintended that the claims submitted herewith define the overall scope.

Various aspects of the subject matter described herein are set out inthe following numbered examples:

EXAMPLE 1

An electrosurgical device, comprising: a cartridge configured to bedisposed within an elongate channel of an end effector, wherein thecartridge comprises an electrode having a plurality of electrodeportions disposed along a longitudinal axis of the cartridge, whereinthe electrode is configured to electrically couple to a generator;wherein each electrode portion of the plurality of electrode portions isconfigured to deliver an amount of energy to a tissue placed proximatethereto; and wherein an amount of energy delivered by a first electrodeportion of the plurality of electrode portions differs from an amount ofenergy delivered by a second electrode portion of the plurality ofelectrode portions.

EXAMPLE 2

The electrosurgical device of Example 1, wherein the cartridge isconfigured to be releasably disposed within the elongate channel.

EXAMPLE 3

The electrosurgical device of one or more of Example 1 through Example2, wherein the plurality of electrode portions comprise a proximal rightelectrode, a distal right electrode, a proximal left electrode, and adistal left electrode.

EXAMPLE 4

The electrosurgical device of Example 3, further comprising a rightflexible circuit and a left flexible circuit, wherein the proximal rightelectrode and the distal right electrode are electrically coupled to theright flexible circuit, and wherein the proximal left electrode and thedistal left electrode are electrically coupled to the left flexiblecircuit.

EXAMPLE 5

The electrosurgical device of Example 4, wherein the right flexiblecircuit and the left flexible circuit each has an overall width of 0.025inches, and wherein the proximal right electrode, the distal rightelectrode, the proximal left electrode and the distal left electrodeeach has a width of 0.010 inches.

EXAMPLE 6

An electrosurgical device, comprising: a cartridge configured to bedisposed within an elongate channel of an end effector, wherein thecartridge comprises an electrode having a plurality of electrodeportions disposed along a longitudinal axis of the cartridge, whereinthe electrode is configured to electrically couple to a generator; aflexible cartridge circuit electrically coupled to the electrode,wherein the flexible cartridge circuit is configured to electricallycouple to a plurality of exposed contacts on a distal end of a channelcircuit disposed within the elongate channel; wherein each electrodeportion of the plurality of electrode portions is configured to deliveran amount of energy to a tissue placed proximate thereto; and wherein anamount of energy delivered by a first electrode portion of the pluralityof electrode portions differs from an amount of energy delivered by asecond electrode portion of the plurality of electrode portions.

EXAMPLE 7

The electrosurgical device of Example 6, wherein the channel circuitfurther comprises a proximal contact portion electrically coupled to adistal contact portion of a flexible shaft circuit strip.

EXAMPLE 8

The electrosurgical device of Example 7, wherein a proximal contactportion of the flexible shaft circuit strip is configured toelectrically couple to the generator.

EXAMPLE 9

An end effector, comprising: a first jaw assembly comprising: anelongate channel; and an electrosurgical cartridge disposed within theelongate channel, wherein the electrosurgical cartridge furthercomprises: a shear electrode having a plurality of shear electrodeportions disposed along a longitudinal axis of the electrosurgicalcartridge; and a dissector electrode disposed at a distal end of theelectrosurgical cartridge; and a second jaw assembly comprising an anvilconfigured to move proximate to a surface of the electrosurgicalcartridge, wherein the shear electrode and the dissector electrode areeach configured to receive electrosurgical energy from anelectrosurgical generator, wherein each shear electrode portion of theplurality of shear electrode portions is configured to deliver an amountof electrosurgical energy to a tissue placed proximate thereto, andwherein an amount of electrosurgical energy delivered by a first shearelectrode portion of the plurality of shear electrode portions differsfrom an amount of electrosurgical energy delivered by a second shearelectrode portion of the plurality of shear electrode portions.

EXAMPLE 10

The end effector of Example 9, wherein the electrosurgical cartridge isreleasably disposed within the elongate channel.

EXAMPLE 11

The end effector of one or more of Example 9 through Example 10, whereinthe first shear electrode portion is proximal to the second shearelectrode portion.

EXAMPLE 12

The end effector of Example 11, wherein the amount of electrosurgicalenergy delivered by the first shear electrode portion is less than theamount of electrosurgical energy delivered by the second shear electrodeportion.

EXAMPLE 13

The end effector of one or more of Example 11 through Example 12,wherein the first shear electrode portion has a first patterned energydelivery surface, and the second shear electrode portion has a secondpatterned energy delivery surface.

EXAMPLE 14

The end effector of Example 13, wherein the first patterned energydelivery surface differs from the second patterned energy deliverysurface.

EXAMPLE 15

The end effector of one or more of Example 13 through Example 14,wherein the first patterned energy delivery surface and the secondpatterned energy delivery surface each comprise a plurality of surfacefeatures.

EXAMPLE 16

The end effector of Example 15, wherein the plurality of surfacefeatures comprises an electrically insulative material.

EXAMPLE 17

The end effector of one or more of Example 15 through Example 16,wherein the first patterned energy delivery surface has a first areadensity of a plurality of surface features, the second patterned energydelivery surface has a second area density of a plurality of surfacefeatures, and the first area density of a plurality of surface featuresis greater than the second area density of a plurality of surfacefeatures.

EXAMPLE 18

The end effector of one or more of Example 15 through Example 17,wherein the plurality of surface features comprises a plurality oftransverse rectilinear features.

EXAMPLE 19

The end effector of one or more of Example 15 through Example 18,wherein the plurality of surface features comprises a plurality ofcircular features.

EXAMPLE 20

The end effector of one or more of Example 15 through Example 19,wherein the plurality of surface features comprises a plurality ofconcave quadrilateral features.

EXAMPLE 21

The end effector of one or more of Example 15 through Example 20,wherein the first patterned energy delivery surface comprises a firstplurality of surface features disposed directly on a surface of thefirst shear electrode portion, and the second patterned energy deliverysurface comprises a second plurality of surface features disposeddirectly on a surface of the second shear electrode portion.

EXAMPLE 22

The end effector of one or more of Example 15 through Example 21,wherein first patterned energy delivery surface comprises a firstplurality of recessed surface features disposed in a surface of thefirst shear electrode portion, and the second patterned energy deliverysurface comprises a second plurality of recessed surface featuresdisposed in a surface of the second shear electrode portion.

EXAMPLE 23

The end effector of one or more of Example 9 through Example 22, whereinthe shear electrode comprises a left shear electrode and a right shearelectrode.

EXAMPLE 24

The end effector of Example 23, wherein the left shear electrodecomprises a plurality of left shear electrode portions disposed along alongitudinal axis of the electrosurgical cartridge, and the right shearelectrode comprises a plurality of right shear electrode portionsdisposed along a longitudinal axis of the electrosurgical cartridge.

EXAMPLE 25

The end effector of Example 24, wherein the left shear electrodecomprises three left shear electrode portions disposed along alongitudinal axis of the electrosurgical cartridge, and the right shearelectrode comprises three right shear electrode portions disposed alonga longitudinal axis of the electrosurgical cartridge.

Cartridge Arrangements for Surgical Cutting and Fastening Instrumentswith Lockout Disablement Features

In a surgical instrument it may be useful to control when the cuttingmember can be advanced through an end effector. In order to control whenthe cutting member may be advanced, the surgical instrument may providea type of lockout mechanism to prevent advancement of the cutting memberin a staple/fastener cartridge in various circumstances. Lockoutmechanisms for staple/fastener cartridge mechanically prevent thecutting member from being advanced by engaging part of the cuttingmember to prohibit distal movement. Preventing advancement of thecutting member may be useful when a surgical cartridge has not beeninserted into the end effector, is improperly inserted into the endeffector, or when the staple/fastener cartridge is spent.

During use of a surgical instrument it is possible that a mechanicalstapling surgical cartridge may be inserted improperly, not inserted atall, or may be spent. Therefore, it may be desirable to provide alockout mechanism that mechanically prevents advancement of a cuttingmember through an end effector when a staple/fastener cartridge isabsent, improperly placed in the end effector, or is spent. Such lockoutmechanisms, however, interfere with the operation of a radio frequency(RF) cartridge configured to be used in an end effector configured toreceive mechanical staple/fastener cartridges and/or radio frequencycartridges. Thus, the present disclosure provides a lockout disablementmechanism to accommodate an RF cartridge in an end effector configuredto receive mechanical staple/fastener cartridges or radio frequencycartridges and includes a lockout mechanism suitable to lockout amechanical staple/fastener cartridge.

As shown in FIGS. 10-12, in at least one arrangement, the RF surgicalcartridge 1700 includes a cartridge body 1710 that is sized and shapedto be removably received and supported in the elongate channel 1602. Forexample, the cartridge body 1710 may be configured to be removablyretained in snap engagement with the elongate channel 1602. In variousarrangements, the cartridge body 1710 may be fabricated from a polymermaterial, such as, for example, an engineering thermoplastic such as theliquid crystal polymer (LCP) VECTRA™ and the elongate channel 1602 maybe fabricated from metal. In at least one aspect, the cartridge body1710 includes a centrally disposed elongate slot 1712 that extendslongitudinally through the cartridge body to accommodate longitudinaltravel of the knife 1330 therethrough. As shown in FIGS. 10 and 11, apair of lockout engagement tails 1714 extends proximally from thecartridge body 1710 to disable the lockout mechanism intended to lockoutthe staple/fastener cartridge 1400. Each lockout engagement tail 1714has a lockout pad 1716 formed on the underside thereof that are sized tobe received within a corresponding proximal opening portion 1642 in thechannel bottom 1620. Thus, when the cartridge 1700 is properly installedin the elongate channel 1602, the lockout engagement tails 1714 coverthe openings 1642 and ledges 1654 to retain the knife 1330 in anunlocked position ready for firing.

Turning now to FIG. 65, with reference still to FIGS. 10-12, in at leastone arrangement, the surgical staple cartridge 1900 includes a cartridgebody 1918 that is sized and shaped to be removably received andsupported in the elongate channel 1602. For example, the cartridge body1918 may be configured to be removably retained in snap engagement withthe elongate channel 1602. In various arrangements, the cartridge body1918 may be fabricated from a polymer material, such as, for example, anengineering thermoplastic such as the liquid crystal polymer (LCP)VECTRA™ and the elongate channel 1602 may be fabricated from metal. Inat least one aspect, the cartridge body 1918 includes a centrallydisposed elongate slot 1912 that extends longitudinally through thecartridge body to accommodate longitudinal travel of the knife 1330therethrough. As shown in FIG. 65, a pair of lockout engagement tails1914 extends proximally from the cartridge body 1918. Each lockoutengagement tail 1914 has a lockout pad 1916 formed on the undersidethereof that are sized to be received within a corresponding proximalopening portion 1642 in the channel bottom 1620. Thus, when thecartridge 1900 is properly installed in the elongate channel 1602, thelockout engagement tails 1914 cover the openings 1642 and ledges 1654 toretain the knife 1330 in an unlocked position ready for firing.

Various aspects of the subject matter described herein are set out inthe following numbered examples:

EXAMPLE 1

A surgical cartridge assembly, comprising: a proximal end; a distal end;an elongate channel, comprising: a base; and at least one opening withinthe base; a cartridge body configured to be removably received withinthe elongate channel; a slot configured to receive a cutting member; atleast one lockout tab extending from the proximal end of the cartridgebody, wherein the at least one lockout tab is configured to cover the atleast one opening when the cartridge body is received within theelongate channel, and wherein the at least one lockout tab disables alockout mechanism to allow the cutting member to advance distallythrough the slot.

EXAMPLE 2

The surgical cartridge assembly of Example 1, wherein the elongatechannel further comprises at least one ledge on the base positioneddistal to the at least one opening.

EXAMPLE 3

The surgical cartridge assembly of Example 2, wherein the at least onelockout tab is configured to cover the at least one ledge when thecartridge body is received within the elongate channel.

EXAMPLE 4

The surgical cartridge assembly of one or more of Example 1 throughExample 3, wherein the at least one lockout tab comprises at least onelockout pad configured to be received within the at least one openingwhen the cartridge body is received within the elongate channel.

EXAMPLE 5

The surgical cartridge assembly of one or more of Example 1 throughExample 4, wherein a portion of the cutting member is configured to bereceived within the at least one opening of the elongate channel in theabsence of a cartridge body.

EXAMPLE 6

The surgical cartridge assembly of one or more of Example 1 throughExample 5, wherein the surgical cartridge assembly comprises a staplecartridge.

EXAMPLE 7

The surgical cartridge assembly of one or more of Example 1 throughExample 6, wherein the surgical cartridge assembly comprises a RFcartridge.

EXAMPLE 8

An end effector for a surgical instrument, the end effector comprising:a proximal end; a distal end; a first jaw; a second jaw comprising anelongate channel including a base, wherein the base of the elongatechannel comprises: a first opening; and a second opening; and a surgicalcartridge configured to be removably received within the elongatechannel, the surgical cartridge comprising: a cartridge body; a slotconfigured to receive a cutting member; a first tab extending from theproximal end of the cartridge body on a first side of the slot, whereinthe first tab is configured to cover the first opening and the firstledge when the surgical cartridge is received within the elongatechannel; and a second tab extending from the proximal end of thecartridge body on a second side of the slot, wherein the second tab isconfigured to cover the second opening and the second ledge when thesurgical cartridge is received within the elongate channel, and whereinthe first tab and the second tab disable a lockout mechanism to allow acutting member to advance distally through the slot.

EXAMPLE 9

The end effector of Example 8, wherein the elongate channel furthercomprises a first ledge and a second ledge, wherein the first ledge ispositioned on the base distal to the first opening, and wherein thesecond ledge is positioned on the base distal to the second opening.

EXAMPLE 10

The end effector of Example 9, wherein the first tab is configured tocover the first ledge when the surgical cartridge is received within theelongate channel, and the second tab is configured to cover the secondledge when the surgical cartridge is received within the elongatechannel.

EXAMPLE 11

The end effector of one or more of Example 8 through Example 10, whereinthe first tab comprises a first pad configured to be received within thefirst opening when the surgical cartridge is received within theelongate channel.

EXAMPLE 12

The end effector of one or more of Example 8 through Example 11, whereina first portion of the cutting member is configured to be receivedwithin the first opening of the elongate channel in the absence of asurgical cartridge, and wherein a second portion of the cutting memberis configured to be received within the second opening of the elongatechannel in the absence of a surgical cartridge.

EXAMPLE 13

The end effector of one or more of Example 8 through Example 12, whereinthe surgical cartridge comprises a staple cartridge.

EXAMPLE 14

The end effector of one or more of Example 8 through Example 13, whereinthe surgical cartridge comprises a RF cartridge.

EXAMPLE 15

A surgical cartridge assembly, comprising: a proximal end; a distal end;an elongate channel, comprising: a base; a first opening; and a secondopening; a surgical cartridge configured to be removably received withinthe elongate channel, the surgical cartridge comprising: a cartridgebody; a longitudinal slot configured to receive a cutting member; afirst lockout projection extending proximally from the proximal end ofthe cartridge body on a first side of the slot, wherein the firstlockout projection is configured to cover the first opening when thesurgical cartridge is received within the elongate channel; and a secondlockout projection extending proximally from the proximal end of thecartridge body on a second side of the slot, wherein the second lockoutprojection is configured to cover the second opening when the surgicalcartridge is received within the elongate channel, and wherein the firstlockout projection and the second lockout projection disable a lockoutmechanism to allow a cutting member to advance distally through theslot.

EXAMPLE 16

The surgical cartridge assembly of Example 15, wherein the elongatechannel further comprises a first ledge on the base positioned distal tothe first opening and a second ledge on the base positioned distal tothe second opening.

EXAMPLE 17

The surgical cartridge assembly of Example 16, wherein the first lockoutprojection is configured to cover the first ledge when the surgicalcartridge is received within the elongate channel, and the secondlockout projection is configured to cover the second ledge when thesurgical cartridge is received within the elongate channel.

EXAMPLE 18

The surgical cartridge assembly of one or more of Example 15 throughExample 17, wherein the first lockout projection comprises a firstlockout pad configured to be received within the first opening when thesurgical cartridge is received within the elongate channel.

EXAMPLE 19

The surgical cartridge assembly of one or more of Example 15 throughExample 18, wherein the surgical cartridge comprises a staple cartridge.

EXAMPLE 20

The surgical cartridge assembly of one or more of Example 15 throughExample 19, wherein the surgical cartridge comprises a RF cartridge.

Surgical Cutting and Fastening Instruments with Dual Power Sources

In a surgical sealing and stapling system, it may be useful to employ amodular design that allows a single handle assembly to attach tomultiple nozzle assemblies, and for a nozzle assembly to attach tomultiple handle assemblies. Since the nozzle assembly would include thevarious surgical instruments in the end effector, special circuitry inthe nozzle may be required to allow for instrumentation in a handleassembly to control the various functions in the end effector of themodular nozzle assembly. In some examples, each of the various surgicalinstruments may be designed to effect a specific surgical function, forexample one or more types of tissue sealing functions. In addition, itmay be necessary to apply energy to the end effector, which may or maynot originate from the handle assembly. For example, the handle assemblymay be battery powered to control the functions of the handle assembly,but may not possess power sufficient to control the end effector.Additionally, a system including a surgical sealing function may havespecific power requirements, for example a requirement for sourcing RFenergy for applying a hemostatic seal to a tissue, which is nototherwise associated with a handle assembly.

A modular design of a surgical system having multiple nozzle assembliesmay include various surgical instruments, each configured for adifferent surgical function. In one example, a nozzle assembly mayinclude an end effector further modularized to accept releasable endeffector cartridges, in which the surgical function is determined by theend effector cartridge. In such an example, circuitry within the nozzleassembly should be capable of conducting electrical signals to the endeffector cartridge as necessary to permit the end effector cartridge tooperate properly. For some surgical procedures, a hemostatic seal may beinduced in the target tissue. Such a hemostatic seal may require theapplication of RF energy to the tissue. Thus, the circuitry may bedesigned to have some electrical conductors configured to deliver the RFenergy to the end effector cartridge. However, the circuitry may haveonly a limited number of electrical conductors. It is thereforedesirable for the circuitry to supply RF energy to the end effector whenneeded through dedicated RF electrical conductors, but to reconfigurethe RF electrical conductors and/or other components of the circuitryfor conducting non-RF energy when RF energy is not required.

In some aspects, a circuitry system is included in the nozzle assemblythat allows for a user of the modular surgical instruments describedherein to manipulate the end effector directly from the instrumentationcontained in the handle assembly. In some examples, the nozzle assemblymay be configured to impart a hemostatic seal to tissue through theapplication of both a clamping force and the application of RF energy tothe tissue. The nozzle assembly may include an onboard circuit boardthat allows for an electrosurgical generator to attach directly to thenozzle assembly and supply radio frequency (RF) energy to the endeffector for such a surgical function. In some aspects, the circuitry ofthe nozzle assembly also allows for shaft rotation while still supplyingproper energy and functionality to the end effector.

It may be recognized that care should be taken to assure that RF energyconducted by some electrical conductors of the onboard circuit board isproperly isolated from any of the other components of the onboardcircuit board. Failure to provide such isolation may result in RF energyor noise being introduced into the other electronic components (such asdigital electronics) or signal conductors of the onboard circuit board.In some aspects, RF energy isolation may be accomplished by isolatingconductors of RF energy to a segmented circuit component of the onboardcircuit board. The segmented circuit component may be configured toincorporate proper electrical conductor geometry, and appropriatelocalization of ground planes around the RF conductors thereby isolatingthe RF energy from the other components of the onboard circuit board.Such a segmented circuit component may be located on a portion of theonboard circuit board physically separated from the other electricalcomponents. In one aspect, connecting the surgical instrument to an RFgenerator enables certain shaft functions. For example, attachment of RFleads to the RF generator allow the surgical instrument onboard circuitboard to isolate some of the elongated shaft integral circuit wiring forRF application to an RF cartridge interchangeably usable with staplingcartridges.

Referring to FIG. 40, in some aspects, the nozzle assembly 1240 thatconstitutes a modular portion of the surgical tool assembly 1000 mayinclude shaft module circuitry configured to control various functionsin the shaft assembly while also communicating with the handle assembly500 and allowing for the RF generator 400 to be controlled from thepowered stapling handle. In FIG. 40, the circuitry of FIG. 15 is shownin the context of an example nozzle assembly 1240. The circuitryaccording to some aspects of the present disclosures includes theonboard circuit board 1152 with various connectors. Female connectors410 are electrically coupled to the circuit board 1152, which allows forconnection with the male plug assembly 406 that couple to the generator400, not shown.

In addition, the onboard on/off power switch 420 is electrically coupledto the circuit board 1152 and positioned in such a way so as to bepressed when the nozzle assembly 1240 is attached to the handle assembly500, according to some aspects. For example, when the nozzle assemblylocks into place (see e.g., FIG. 9), the on/off power switch 420 may bepositioned to face proximally to the handle assembly and may be pressedas the nozzle assembly slides into the slot of the handle assembly viathe closure link 514 (see FIG. 9). In other cases, the on/off powerswitch 420 is exposed so that it may be manually pressed by an operatorof the surgical tool assembly 1000.

The circuit board 1152 includes the onboard connector 1154 configured tointerface with the housing connector 562 (see FIG. 9) communicating withthe microprocessor 560 contained in the handle assembly 500. In thisway, the handle assembly 500 is capable of communicating with thecircuit board 1152 that controls several functions in the nozzleassembly 1240. Electrical power, for example from the power assembly706, may also be conducted through the onboard connector 1154 to theonboard circuit board 1152. The design of the circuitry in the nozzleassembly 1240 allows for an operator to perform a number of functionsfrom the various controls of the handle assembly 500, such as throughthe various controls and display consoles available in the handleassembly 500.

The circuit board 1152 also includes the proximal connector 1153 that isconfigured to interface with the slip ring assembly 1150. Power may besupplied to the end effector even while the shaft rotates due to powerbeing supplied throughout the slip ring assembly 1150 and the distalconnector 1162 being in constant contact with the slip ring assembly asthe flexible shaft circuit strip 1164 rotates within the proximalclosure tube 1910. The shaft circuit strip 1164 may include a number ofelectrical conductors, such as the narrow electrical conductors 1166 forstapling related activities and the wider electrical conductors 1168 forRF purposes (see FIG. 15).

Based on the various components described in the nozzle assembly 1240,the circuitry 1152 may be configured to control the RF generator 400from the powered handle assembly 500, allowing for communication withthe various functions and interfaces of the handle assembly 500, andallowing for operation of the RF and stapling functions of the endeffector from the handle assembly 500. Other functions may includecontrolling a type of algorithm for performing various surgicalprocedures and energy applications at the end effector, enabling warningfunctionality viewable at the handle assembly 500 of any part of thenozzle assembly 1240, and varying energy modulation from the RFgenerator 400. In some aspects, the circuit board 1152 may be programmedto facilitate these functions, while in other cases the onboardconnecter 1154 may allow for the handle assembly circuitry to beprogrammed to facilitate these functions and the circuit board 1152 isconfigured to communicate with the end effector accordingly.

In some aspects, the onboard circuit 1152 includes the segmented RFcircuit 1160, which may allow for the RF energy of the generator 400 tobe supplied to the flexible shaft circuit strip via the slip ringassembly (see, e.g., FIG. 15). The segmented RF circuit 1160 mayincorporate electrical conductors for supplying the RF energy andprovide electrical isolation of the other components of the onboardcircuit board 1152 from RF energy and/or noise. The RF generator may becoupled to the onboard circuit board 1152 via the RF segmented circuit1160. The on/off power switch 420 may be similarly connected to thesegmented RF circuit 1160.

FIG. 41 illustrates a block diagram of a surgical system 3200 programmedto conduct power and control signals to or from an end effector 3250according to one aspect of this disclosure. In an example aspect, thesurgical system 3200 may include a control circuit 3210 (e.g.,microprocessor 560, segmented RF circuit 1160, or distal micro-chip1740) having an electrosurgical energy control segment (or an RF energycontrol segment) 3220 and a shaft control segment 3230 (e.g., shaftsegment (Segment 5), motor circuit segment (Segment 7), or power segment(Segment 8)). In some aspects, the electrosurgical energy controlsegment 3220 may be localized on, in, or proximate to the segmented RFcircuit 1160 of the onboard circuit board 1152. The control circuit 3210may be programed to provide electrosurgical energy (e.g., RF energy) tothe electrodes (e.g., electrodes 3040L, 3040R, 3050L, 3050R) in the endeffector 3250 (e.g., end effector 1500). The surgical system 3200 mayinclude one or more electrical conductors 3260 (e.g., electricalconductors 1168) used for providing the electrosurgical energy, from anelectrosurgical energy generator 3240 (e.g., RF generator 400), to theend effector 3250. The one or more electrical conductors 3260 may alsobe electrically connected between the end effector 3250 and the controlcircuit 3210 (e.g., the electrosurgical energy control segment 3220 andthe shaft control segment 3230). The electrical conductors 3260 mayprovide additional control signals to the end effector 3250 from theshaft control segment 3230 or provide additional sensor signals from theend effector 3250 to the shaft control segment 3230, especially forsurgical systems having an end effector not requiring RF energy for itsfunction.

The electrosurgical energy control segment 3220 may be programed toprovide the electrosurgical energy to the electrodes through the one ormore electrical conductors 3260. In an example aspect, the shaft controlsegment 3230 may be programed to provide and/or receive a control signalto/from the end effector 3250 (and/or the surgical tool assembly 1000,the shaft assembly 704) through the one or more electrical conductors3260. That is, the one or more electrical conductors 3260 may be usednot only for providing the electrosurgical energy to the end effector3250, but also for communicating control signals with the end effector3250. In an example aspect, at least some portions of theelectrosurgical energy control segment 3220 and the shaft controlsegment 3230 may be electrically isolated from each other.

In an example aspect, the electrosurgical energy control segment 3220may electrically isolate the one or more electrical conductors 3260 fromthe shaft control segment 3230, for example, when providing theelectrosurgical energy to the electrodes in the end effector 3250through the one or more electrical conductors 3260. In an exampleaspect, the electrosurgical energy control segment 3220 may control aswitch 3270 located between the one or more electrical conductors 3260and the shaft control segment 3230 by providing a signal through acontrol line 3280 to electrically isolate the one or more electricalconductors 3260 from the shaft control segment 3230. The switch 3270 maybe configured to switch between an open state and a closed state. Theshaft control segment 3230 and the one or more electrical conductors3260 may be electrically isolated when the switch 3270 is in the openstate, and may be in electrical communication when the switch 3270 is inthe closed state. In another example aspect, the electrosurgical energycontrol segment 3220 may electrically isolate the one or more electricalconductors 3260 from the shaft control segment 3230 in any othersuitable manner. Other configurations of the switch 3270 may enableelectrical isolation of the one or more electrical conductors 3260 fromthe shaft control segment 3230 by closing the switch 3270.

In an example aspect, the electrosurgical energy control segment 3220may electrically isolate the one or more electrical conductors 3260 fromthe shaft control segment 3230 when the control circuit 3210 detectsthat the electrosurgical energy generator 3240 is connected to theconnector 3265 (e.g., female connectors 410), for example, bycontinuously checking the connector 3265 or sensing the application ofthe electrosurgical energy. For example, when the male plug assembly 406is plugged into the female connectors 410, the electrosurgical energycontrol segment 3220 may isolate the electrical conductors 3260 from theshaft control segment 3230. In another example aspect, theelectrosurgical energy control segment 3220 may electrically isolate theone or more electrical conductors 3260 from the shaft control segment3230 when the electrosurgical energy is provided to the end effector3250 or under any other suitable condition.

In an example aspect, the surgical system may include one or moreelectrical conductors 3290 (e.g., electrical conductors 1166) used foroperating the end effector 3250 (and/or the surgical tool assembly 1000,the shaft assembly 704). In an example aspect, the one or moreelectrical conductors 3290 may not be used to deliver theelectrosurgical energy to the end effector 3250. The shaft controlsegment 3230 may be programed to provide and/or receive a control signaland/or a sensor signal to/from the end effector 3250 through the one ormore electrical conductors 3290. In an example aspect, the shaft controlsegment 3230 may use the one or more electrical conductors 3290 toprovide and/or receive the control signal to/from the end effector 3250while the switch 3270 is in an open state (e.g., while theelectrosurgical energy control segment 3220 is providing theelectrosurgical energy to the end effector 3250 through the one or moreelectrical conductors 3260). In an example aspect, the shaft controlsegment 3230 also may use the one or more electrical conductors 3290 toprovide and/or receive the control signal to/from the end effector 3250while the switch 3270 is in a closed state. In some aspects, the one ormore electrical conductors 3290 may be dedicated signal conductors (foreither control signals or sensor signals or both control signals andsensor signals) between the end effector 3250 and the shaft controlsegment 3230 regardless of the state of switch 3270.

The switch 3270 may be a transistor switch, a mechanical switch, or anyother suitable switch. In an example aspect, the control signalscommunicated between the control circuit 3210 and the end effector 3250(and/or the surgical tool assembly 1000, the shaft assembly 704) throughthe electrical conductors 3260, 3290 include, but are not limited to,signals for driving the end effector 3250 (and/or the surgical toolassembly 1000, the shaft assembly 704) in cutting and/or coagulationoperating modes, measuring electrical characteristics of the surgicalsystem 3200 and/or the tissue clamped in the end effector 3250,providing feedback to a user of the surgical system, communicatingsensor signals, and identifying certain characteristics of the endeffector 3250 (e.g., used/unused status).

Accordingly, aspects of the present disclosure may advantageously reducethe number of electrical conductors necessary for communicating controlsignals between the control circuit 3210 and the end effector 3250(and/or the surgical tool assembly 1000, the shaft assembly 704) byusing some of the electrical conductors (e.g., electrical conductors3260) used for the delivery of the electrosurgical energy to communicatethe control signals when those electrical conductors are not used forthe electrosurgical energy. Moreover, by isolating those electricalconductors from other circuit segments (e.g., shaft control segment3230) when providing the electrosurgical energy through those electricalconductors, aspects of the present disclosure may prevent theelectrosurgical energy or electrosurgical energy noise from flowing intothe other circuit segments and/or electrical conductors (e.g.,electrical conductors 3290) connected to those circuit segments,preventing damages to those circuit segments and/ore electricalconductors.

As depicted in, for example in FIGS. 40 and 41 and as disclosed above, amodular nozzle assembly may include an onboard circuit board configuredto permit a user to communicate with and control an end effector of asurgical system. The control of and/or communication with the endeffector may include control and/or communication with the end effectoras a whole or with any one or more components of the end effector. Forexample, the end effector may be configured to releasably incorporateone or more modules and/or cartridges as disclosed above, each of whichmay be designed for a specific surgical function. In one example, theend effector may incorporate a releasable stapling cartridge. In anotherexample, the end effector may incorporate a releasable RF cartridge.Each of the releasable cartridges may have any number or type ofelectrical conductors configured to electrically couple with the one ormore electrical conductors of the onboard circuit board. The electricalconductors of each releasable cartridge may be configured to conduct anytype of electrical signal, including, without limitation, an analogsignal, a digital signal, a DC signal, an AC signal, and an electricalpower signal. Such electrical signals may originate from the onboardcircuit board or from electrical components of a releasable cartridge.

Although the electrical circuitry as disclosed above is referred to asan onboard “circuit board,” the circuitry itself may be fabricatedaccording to any appropriate means using any appropriate material. Thus,for example, the circuit board may be a single layer board, amulti-layer board, a flex circuit, or any other appropriate device onwhich electrical components may be suitably mounted. Similarly,electrical conductors may include, without limitation, wires and circuitboard traces.

Various aspects of the subject matter described herein are set out inthe following numbered examples:

EXAMPLE 1

A control circuit for a surgical instrument, the control circuitcomprising: a shaft control segment; a first electrical conductorconfigured to conduct a first electrical signal between the shaftcontrol segment and a releasable surgical instrument cartridge; anelectrosurgical energy control segment; a second electrical conductorconfigured to conduct a second electrical signal between theelectrosurgical energy control segment and the releasable surgicalinstrument cartridge; and a connector electrically coupled to theelectrosurgical energy control segment and configured to receiveelectrosurgical generator energy from an electrosurgical generator,wherein the electrosurgical energy control segment is configured to:detect a connection of the electrosurgical generator to the connector;and electrically isolate the shaft control segment from theelectrosurgical generator energy when the electrosurgical energy controlsegment detects the connection of the electrosurgical generator to theconnector.

EXAMPLE 2

The control circuit of Example 1, wherein the first electrical signalcomprises a control signal transmitted to the releasable surgicalinstrument cartridge.

EXAMPLE 3

The control circuit of any one or more of Example 1 through Example 2,wherein the first electrical signal comprises a sensor signal receivedfrom the releasable surgical instrument cartridge.

EXAMPLE 4

The control circuit of any one or more of Example 1 through Example 3,wherein the second electrical signal comprises the electrosurgicalgenerator energy when the electrosurgical energy control segment detectsthe connection of the electrosurgical generator to the connector.

EXAMPLE 5

The control circuit of any one or more of Example 1 through Example 4,wherein the second electrical conductor is configured to conduct a thirdelectrical signal between the shaft control segment and the releasablesurgical instrument cartridge when the electrosurgical energy controlsegment detects no connection of the electrosurgical generator to theconnector.

EXAMPLE 6

The control circuit of Example 5, wherein the third electrical signalcomprises a second control signal transmitted to the releasable surgicalinstrument cartridge.

EXAMPLE 7

The control circuit of Example 5, wherein the third electrical signalcomprises a second sensor signal received from the releasable surgicalinstrument cartridge

EXAMPLE 8

The control circuit of any one or more of Example 1 through Example 7,further comprising a switch electrically coupled between theelectrosurgical energy control segment and the shaft control segment,wherein the electrosurgical energy control segment is configured toelectrically isolate the shaft control segment by controlling theswitch.

EXAMPLE 9

The control circuit of Example 8, wherein the electrosurgical energycontrol segment is configured to electrically isolate the shaft controlsegment by opening the switch.

EXAMPLE 10

The control circuit of any one or more of Example 1 through Example 9,wherein the electrosurgical generator comprises an RF generator and theelectrosurgical generator energy comprises RF energy.

EXAMPLE 11

The control circuit of any one or more of Example 1 through Example 10,further comprising a slip ring assembly electrically coupled to theshaft control segment and electrically coupled to the electrosurgicalenergy control segment.

EXAMPLE 12

A nozzle assembly of a surgical system comprising: an onboard circuitboard comprising a shaft control segment and an electrosurgical energycontrol segment; a first electrical conductor configured to conduct afirst electrical signal between the shaft control segment and areleasable surgical instrument cartridge in an end effector; a secondelectrical conductor configured to conduct a second electrical signalbetween the electrosurgical energy control segment and the releasablesurgical instrument cartridge in the end effector; an onboard connectorcoupled to the onboard circuit board and proximally located on thenozzle assembly, the onboard connector configured to interface with ahousing connector of a handle assembly when the nozzle assembly isattached to the handle assembly; a connector electrically coupled to theelectrosurgical energy control segment and configured to receiveelectrosurgical generator energy from an electrosurgical generator; anda shaft attachment lug proximally located on the nozzle assembly andconfigured to be coupled to an attachment cradle of the handle assemblyto attach the nozzle assembly to the handle assembly, wherein theelectrosurgical energy control segment is configured to: detect aconnection of the electrosurgical generator to the connector; andelectrically isolate the shaft control segment from the electrosurgicalgenerator energy when the electrosurgical energy control segment detectsthe connection of the electrosurgical generator to the connector.

EXAMPLE 13

The nozzle assembly of Example 12, wherein the onboard circuit boardcomprises a segmented RF circuit on the onboard circuit board and thesegmented RF circuit comprises the electrosurgical energy controlsegment.

EXAMPLE 14

The nozzle assembly of any one or more of Example 12 through Example 13,wherein the onboard circuit board is configured to receive electricalpower from a power assembly releasably mounted to the handle assembly.

EXAMPLE 15

The nozzle assembly of Example 14, wherein the onboard circuit board isconfigured to receive electrical power through the onboard connector.

EXAMPLE 16

The nozzle assembly of any one or more of Example 12 through Example 15,wherein the nozzle assembly further comprises a power switchelectrically coupled to the onboard circuit board and is configured toactivate and deactivate transmission of electrosurgical energy.

EXAMPLE 17

The nozzle assembly of any one or more of Example 12 through Example 16,further comprising a slip ring assembly distally located to the onboardcircuit board and configured to interface with the onboard circuitboard.

EXAMPLE 18

The nozzle assembly of Example 17, further comprising: a proximalconnector coupled to a distal end of the onboard circuit board and aproximal end of the slip ring assembly; and a distal connectorconfigured to interface with a distal end of the slip ring assembly andelectrically coupled to the first electrical conductor and the secondelectrical conductor.

EXAMPLE 19

The nozzle assembly any one or more of Example 12 through Example 19,further comprising a flexible shaft circuit strip electrically coupledto the first electrical conductor and the second electrical conductor.

Surgical System Couplable with Staple Cartridge and Radio FrequencyCartridge, and Method of Using Same

FIG. 66 illustrates a method 1950 of utilizing the interchangeable toolassembly 1000 according to various aspects. For a first procedure, thesurgical staple/fastener cartridge 1400 may be inserted 1952 into andretained within the elongate channel 1602 of the first jaw 1600 of theend effector 1500 of the interchangeable surgical tool assembly 1000,thereby coupling the surgical staple/fastener cartridge 1400 to theinterchangeable surgical tool assembly 1000. The surgicalstaple/fastener cartridge 1400 may then be utilized to deliver 1954staples from the surgical staple/fastener cartridge 1400 to a tissue ina patient.

After at least some of the staples are delivered to the tissue in thepatient, the surgical staple/fastener cartridge 1400 may be removed 1956from the end effector 1500 of the interchangeable surgical tool assembly1000, effectively uncoupling the surgical staple/fastener cartridge 1400from the interchangeable surgical tool assembly 1000. For instanceswhere at least a portion of the interchangeable surgical tool assembly1000 is positioned within the patient's body, the end effector 1500 isremoved from the patient's body prior to the removal of the surgicalstaple/fastener cartridge 1400 from the end effector 1500. Theinterchangeable tool assembly 1000, or portions thereof, may then becleaned and sterilized to properly prepare the interchangeable toolassembly 1000 for subsequent use.

After the surgical staple/fastener cartridge 1400 has been removed fromthe end effector 1500 of the interchangeable surgical tool assembly1000, for a second procedure, the radio-frequency cartridge 1700 may beinserted 1958 into and retained within the elongate channel 1602 of thefirst jaw 1600 of the end effector 1500 of the interchangeable surgicaltool assembly 1000, thereby coupling the radio-frequency cartridge 1700to the interchangeable surgical tool assembly 1000 and effectivelyreplacing the surgical staple/fastener cartridge 1400. Once theradio-frequency cartridge 1700 is in place and the radio-frequencygenerator 400 is coupled to the segmented radio-frequency circuit 1160of the interchangeable surgical tool assembly 1000, the radio-frequencycartridge 1700 may then be utilized to deliver 1960 radio-frequencyenergy (e.g., coagulating electrical current) to a tissue in a patient.The first procedure occurs during a first time period and the secondprocedure occurs during a second time period. The second procedure maybe a continuation of, or different from the first procedure. Therefore,the tissue receiving the radio-frequency energy may be the same generaltissue which previously received the staples, or may be a differenttissue from the tissue which previously received the staples. Similarly,the patient associated with the first procedure may be the same as, ordifferent from, the patient associated with the second procedure.

After at least some of the radio-frequency energy is delivered to thetissue in the patient, the radio-frequency cartridge 1700 may be removed1962 from the end effector 1500 of the interchangeable surgical toolassembly 1000, effectively uncoupling the radio-frequency cartridge 1700from the interchangeable surgical tool assembly 1000. Once theradio-frequency cartridge is removed from the interchangeable toolassembly 1000, the segmented radio-frequency circuit 1160 of theinterchangeable surgical tool assembly 1000 may also be uncoupled fromthe radio-frequency generator 400. For instances where at least aportion of the interchangeable surgical tool assembly 1000 is positionedwithin the patient's body, the end effector 1500 is removed from thepatient's body prior to the removal of the radio-frequency cartridge1700 from the end effector 1500. The interchangeable tool assembly 1000,or portions thereof, may then be cleaned and sterilized to properlyprepare the interchangeable tool assembly 1000 for subsequent use. Eachinstance of such subsequent use can involve either the surgicalstaple/fastener cartridge 1400 (effectively replacing theradio-frequency cartridge 1700) or the radio-frequency cartridge 1700.

Although the above description of the method 1950 describes the surgicalstaple/fastener cartridge 1400 being utilized with the interchangeablesurgical tool assembly 1000 for a first procedure and theradio-frequency cartridge 1700 being utilized with the interchangeablesurgical tool assembly 1000 for a second procedure, the above-describedmethod 1950 is not strictly limited to the described order of the usesor to strictly alternating uses of the surgical staple/fastenercartridge 1400 and the radio-frequency cartridge 1700. For example, asshown in FIG. 66, the radio-frequency cartridge 1700 may be utilized bythe interchangeable surgical tool assembly 1000 for an initial procedureand the surgical staple/fastener cartridge 1400 may be utilized for asubsequent procedure. Also, the interchangeable surgical tool assembly1000 may utilize respective surgical staple/fastener cartridges 1400 forany number of sequential procedures before utilizing the radio-frequencycartridge 1700 for a subsequent procedure (or respective radio-frequencycartridges 1700 1400 for any number of subsequent procedures). Whenrespective surgical staple/fastener cartridges 1400 are usedsequentially, the respective surgical staple/fastener cartridges 1400may be the same or different. For example, one of the respectivesurgical staple/fastener cartridges 1400 may have an effectivelongitudinal stapling length which is different from an effectivelongitudinal stapling length of a different one of the respectivesurgical staple/fastener cartridges 1400. Similarly, the interchangeablesurgical tool assembly 1000 may utilize respective radio-frequencycartridges 1700 for any number of sequential procedures prior toutilizing the surgical staple/fastener cartridge 1400 for a subsequentprocedure (or respective surgical staple/fastener cartridges 1400 forany number of subsequent procedures). When respective radio-frequencycartridges 1700 are used sequentially, the respective radio-frequencycartridges 1700 may be the same or different.

Various aspects of the subject matter described herein are set out inthe following numbered examples:

EXAMPLE 1

A method is provided. The method comprises delivering staples from asurgical staple cartridge of a surgical instrument to a first tissueduring a first procedure, removing the surgical staple cartridge fromthe surgical instrument, and delivering radio-frequency energy from aradio-frequency cartridge of the surgical instrument to a second tissueduring a second procedure.

EXAMPLE 2

The method of Example 1, wherein the delivering of the radio-frequencyenergy from the radio-frequency cartridge occurs before the deliveringof the staples from the surgical staple cartridge.

EXAMPLE 3

The method of one or more of Example 1 through Example 2, wherein thesecond procedure is different from the first procedure.

EXAMPLE 4

The method of one or more of Example 1 through Example 3, furthercomprising inserting the surgical staple cartridge into the surgicalinstrument prior to the delivering of the staples.

EXAMPLE 5

The method of Example 4, wherein inserting the surgical staple cartridgeinto the surgical instrument comprises inserting the surgical staplecartridge into an interchangeable tool assembly.

EXAMPLE 6

The method of one or more of Example 1 through Example 5, furthercomprising, prior to the delivering of the radio-frequency energy,inserting a second surgical staple cartridge into the surgicalinstrument.

EXAMPLE 7

The method of one or more of Example 1 through Example 6, furthercomprising, prior to the delivering of the radio-frequency energy, (1)inserting the radio-frequency cartridge into the surgical instrument and(2) coupling the radio-frequency cartridge to a radio-frequencygenerator.

EXAMPLE 8

The method of Example 7, wherein inserting the radio-frequency cartridgeinto the surgical instrument comprises inserting the radio-frequencycartridge into an interchangeable tool assembly.

EXAMPLE 9

The method of one or more of Example 1 through Example 8, furthercomprising removing the radio-frequency cartridge from the surgicalinstrument.

EXAMPLE 10

The method of Example 9, further comprising inserting a secondradio-frequency cartridge into the surgical instrument.

EXAMPLE 11

The method of Example 9, further comprising inserting a second surgicalstaple cartridge into the surgical instrument.

EXAMPLE 12

A method of utilizing an interchangeable tool assembly is provided. Themethod comprises utilizing a staple cartridge coupled to theinterchangeable tool assembly to deliver staples to seal a first tissueduring the first period of time, replacing the staple cartridge, andutilizing a radio-frequency cartridge coupled to the interchangeabletool assembly to deliver radio-frequency energy to seal a second tissueduring the second period of time.

EXAMPLE 13

The method of Example 12, wherein replacing the staple cartridgecomprises (1) uncoupling the staple cartridge from the interchangeabletool assembly and (2) coupling the radio-frequency cartridge to theinterchangeable tool assembly.

EXAMPLE 14

The method of one or more of Example 12 through Example 13, whereincoupling the radio-frequency cartridge to the interchangeable toolassembly comprises coupling the radio-frequency cartridge to an endeffector of the interchangeable tool assembly.

EXAMPLE 15

The method of one or more of Example 12 through Example 14, furthercomprising, prior to the utilizing of the staple cartridge, coupling thestaple cartridge to an end effector of the interchangeable toolassembly.

EXAMPLE 16

The method of one or more of Example 12 through Example 15, furthercomprising, prior to utilizing the radio-frequency cartridge, (1)coupling the radio-frequency cartridge to the interchangeable toolassembly and (2) coupling the interchangeable tool assembly to aradio-frequency generator.

EXAMPLE 17

The method of one or more of Example 12 through Example 16, furthercomprising coupling a second staple cartridge to the interchangeabletool assembly.

EXAMPLE 18

The method of one or more of Example 12 through Example 17, furthercomprising coupling a second radio-frequency cartridge to theinterchangeable tool assembly.

EXAMPLE 19

A method is provided. The method comprises sealing a first tissue withstaples from a removable staple cartridge of a surgical instrument,sterilizing the surgical instrument, and sealing a second tissue withradio-frequency energy delivered by a removable radio-frequencycartridge of the surgical instrument.

Aspects of the surgical instrument may be practiced without the specificdetails disclosed herein. Some aspects have been shown as block diagramsrather than detail. Parts of this disclosure may be presented in termsof instructions that operate on data stored in a computer memory.Generally, aspects described herein which can be implemented,individually and/or collectively, by a wide range of hardware, software,firmware, or any combination thereof can be viewed as being composed ofvarious types of “electrical circuitry.” Consequently, “electricalcircuitry” includes electrical circuitry having at least one discreteelectrical circuit, electrical circuitry having at least one integratedcircuit, electrical circuitry having at least one application specificintegrated circuit, electrical circuitry forming a general purposecomputing device configured by a computer program (e.g., a generalpurpose computer or processor configured by a computer program, which atleast partially carries out processes and/or devices described herein),electrical circuitry forming a memory device (e.g., forms of randomaccess memory), and/or electrical circuitry forming a communicationsdevice (e.g., a modem, communications switch, or optical-electricalequipment). These aspects may be implemented in analog or digital form,or combinations thereof.

The foregoing description has set forth aspects of devices and/orprocesses via the use of block diagrams, flowcharts, and/or examples,which may contain one or more functions and/or operation. Each functionand/or operation within such block diagrams, flowcharts, or examples canbe implemented, individually and/or collectively, by a wide range ofhardware, software, firmware, or virtually any combination thereof. Inone aspect, several portions of the subject matter described herein maybe implemented via Application Specific Integrated Circuits (ASICs),Field Programmable Gate Arrays (FPGAs), digital signal processors(DSPs), Programmable Logic Devices (PLDs), circuits, registers and/orsoftware components, e.g., programs, subroutines, logic and/orcombinations of hardware and software components, logic gates, or otherintegrated formats. Some aspects disclosed herein, in whole or in part,can be equivalently implemented in integrated circuits, as one or morecomputer programs running on one or more computers (e.g., as one or moreprograms running on one or more computer systems), as one or moreprograms running on one or more processors (e.g., as one or moreprograms running on one or more microprocessors), as firmware, or asvirtually any combination thereof, and that designing the circuitryand/or writing the code for the software and or firmware would be wellwithin the skill of one of skill in the art in light of this disclosure.

The mechanisms of the disclosed subject matter are capable of beingdistributed as a program product in a variety of forms, and that anillustrative aspect of the subject matter described herein appliesregardless of the particular type of signal bearing medium used toactually carry out the distribution. Examples of a signal bearing mediuminclude the following: a recordable type medium such as a floppy disk, ahard disk drive, a Compact Disc (CD), a Digital Video Disk (DVD), adigital tape, a computer memory, etc.; and a transmission type mediumsuch as a digital and/or an analog communication medium (e.g., a fiberoptic cable, a waveguide, a electrical conductor communications link, aelectrical conductorless communication link (e.g., transmitter,receiver, transmission logic, reception logic, etc.).

The foregoing description of these aspects has been presented forpurposes of illustration and description. It is not intended to beexhaustive or limiting to the precise form disclosed. Modifications orvariations are possible in light of the above teachings. These aspectswere chosen and described in order to illustrate principles andpractical application to thereby enable one of ordinary skill in the artto utilize the aspects and with modifications as are suited to theparticular use contemplated. It is intended that the claims submittedherewith define the overall scope.

The invention claimed is:
 1. A method of using a surgical instrumentcomprising an end effector configured to receive multiple cartridges,the method comprising: delivering staples from a surgical staplecartridge inserted into the end effector of the surgical instrument to afirst tissue during a first procedure; removing the surgical staplecartridge from the surgical instrument end effector; opening a switchdispositioned between a first circuit segment and a second circuitsegment to electrically isolate the first circuit segment from thesecond circuit segment without removing the end effector from thesurgical instrument, wherein the first circuit segment is configured todeliver radio-frequency energy to a radio-frequency cartridge; anddelivering radio-frequency energy from the radio-frequency cartridge ofthe surgical instrument to a second tissue during a second procedure. 2.The method of claim 1, wherein the delivering of the radio-frequencyenergy from the radio-frequency cartridge occurs before the deliveringof the staples from the surgical staple cartridge.
 3. The method ofclaim 1, wherein the second procedure is different from the firstprocedure.
 4. The method of claim 1, further comprising inserting thesurgical staple cartridge into the surgical instrument prior to thedelivering of the staples.
 5. The method of claim 4, wherein insertingthe surgical staple cartridge into the surgical instrument comprisesinserting the surgical staple cartridge into an interchangeable toolassembly.
 6. The method of claim 1, further comprising, prior to thedelivering of the radio-frequency energy, inserting a second surgicalstaple cartridge into the surgical instrument.
 7. The method of claim 1,further comprising, prior to the delivering of the radio-frequencyenergy: inserting the radio-frequency cartridge into the surgicalinstrument; and coupling the radio-frequency cartridge to aradio-frequency generator.
 8. The method of claim 7, wherein insertingthe radio-frequency cartridge into the surgical instrument comprisesinserting the radio-frequency cartridge into an interchangeable toolassembly.
 9. The method of claim 1, further comprising removing theradio-frequency cartridge from the surgical instrument.
 10. The methodof claim 9, further comprising inserting a second radio-frequencycartridge into the surgical instrument.
 11. The method of claim 9,further comprising inserting a second surgical staple cartridge into thesurgical instrument.
 12. The method of claim 1, further comprising:detecting a connection of the surgical instrument to a radio-frequencyenergy generator; and wherein opening the switch to electrically isolatethe first circuit segment from the second circuit segment occursautomatically in response to the surgical instrument being connected tothe radio-frequency energy generator in response to the detection of theconnection of the surgical instrument to the radio-frequency energygenerator.
 13. The method of claim 1, wherein the second circuit segmentis a shaft control segment configured to transmit control signals to andfrom the end effector, and wherein opening the switch prohibits theshaft control segment from transmitting control signals to and from theend effector.
 14. A method of utilizing an interchangeable toolassembly, the method comprising: utilizing a staple cartridge coupled tothe interchangeable tool assembly to deliver staples to seal a firsttissue during a first period of time; replacing the staple cartridge;electrically isolating a first circuit segment configured to deliverradio-frequency energy from a second circuit segment by opening a switchdispositioned between the first circuit segment and the second circuitsegment, without decoupling a structural component from theinterchangeable tool assembly, wherein the second circuit segment is ashaft control segment configured to transmit control signals to and froman end effector, and wherein opening the switch prohibits the shaftcontrol segment from transmitting control signals to and from the endeffector; and utilizing a radio-frequency cartridge coupled to theinterchangeable tool assembly to deliver radio-frequency energy to seala second tissue during a second period of time.
 15. The method of claim14, wherein replacing the staple cartridge comprises: uncoupling thestaple cartridge from the interchangeable tool assembly; and couplingthe radio-frequency cartridge to the interchangeable tool assembly. 16.The method of claim 15, wherein coupling the radio-frequency cartridgeto the interchangeable tool assembly comprises coupling theradio-frequency cartridge to the end effector of the interchangeabletool assembly.
 17. The method of claim 14, further comprising, prior tothe utilizing of the staple cartridge, coupling the staple cartridge tothe end effector of the interchangeable tool assembly.
 18. The method ofclaim 14, further comprising, prior to utilizing the radio-frequencycartridge: coupling the radio-frequency cartridge to the interchangeabletool assembly; and coupling the interchangeable tool assembly to aradio-frequency generator.
 19. The method of claim 14, furthercomprising coupling a second staple cartridge to the interchangeabletool assembly.
 20. The method of claim 14, further comprising coupling asecond radio-frequency cartridge to the interchangeable tool assembly.21. A method of using a surgical instrument comprising an end effectorconfigured to receive multiple cartridges, the method comprising:sealing a first tissue with staples from a removable staple cartridge ofthe surgical instrument; sterilizing the surgical instrument;electrically isolating a first circuit segment configured to deliverradio-frequency energy from a second circuit segment by opening a switchdispositioned between the first circuit segment and the second circuitsegment, without removing the end effector from the surgical instrument;and sealing a second tissue with radio-frequency energy delivered by aremovable radio-frequency cartridge of the surgical instrument.